Welcome

Pro-QMS is a software tool, which helps you to build quality-related database and prepare quality plans. There is a facility that enables online control over the quality by directly capturing data from measuring instruments, comparing it with quality plans and doing instant analysis

Overview of Pro QMS

Overview of Dashboard

Overview of Email & SMS Facility


Location Parameter

The Location Parameter Screen displays the Machine Number and the Operation run on that Machine Number. This Screen displays various operations performed on various machines.  Click on ADD and select the select the location. It will display all the parameters in the list view from Part Parameter screen. User can select the parameter by clicking Check box.  When user clicks on save it will show all the parameter in the list view of selected location.

Click on Modify it will display all the parameters in the List view i.e. some parameter is with selected checked box and some parameter is with unchecked box. i.e. Selected Checked box means all those parameters are located from selected location. And unchecked box means all those parameters are not located from selected location.


Shared Folder Path of Excel files

Use this option to provide details about the path of Excel or CSV files.

System will provide the grid for entering record for share folder and test box for Data Fetching Frequency (In Min).

Click Modify to modify the selected record in a grid and then click on Save button.

Click Delete the record to delete the selected record in a grid.

Click on Add to add a record then the system will show all the entered records in a grid and adds one blank row at the end to select the share folder path.

When no record found in database then only Add button will get enabled.

If records exists then Add, Modify and Delete button will get enabled.


Monthly Zip files

Monthly zip files will get created from the History Files, Process Time folder, and put it

in the Zip files folder of the application path.  After zipping, files will get deleted from the History folder of the application folder.  Previous month files can be zipped on 1st or 2nd or 3rd day of current month.

Current monthly files cannot be zipped.


Search Facility of Roll Number

The Search for Roll Number Screen by its name searches for the Roll Numbers. Once the Roll number is found then it tells you how many jobs that selected roll number has processed.


Parameter wise Roll Report with Location and Operator/Employee

The Parameter wise Roll Report displays the Parameter wise data along with the Location and the Operator / Employee


Roll Report

Click on Reports, which will launch Roll Quality Report screen.

The user can select the Period from, Period to and click on OK button, which will launch the roll quality report for current as well as history Jobs. It contains all the Roll number for the specified period.

The user can select or enter roll no and click on OK button, which will launch the roll quality report for that roll number only.


Batch Report

Click on Reports; select Batch Quality Report, which will launch Batch Quality Report screen.

The user can select the Period from, Period to and click on OK button, which will launch the batch quality report for current as well as history Jobs. It contains all the batch number with the roll numbers for the specified period.

The user can select period from, period to, batch no, roll no and click on OK button, which will launch the batch quality report for the selected batch number and roll nos.


Aggregation Report

Click on Aggregation Report or chart; which displays the screen Aggregation Selection where the user has to select either daily, weekly, monthly and click on Ok button which will launch screen for accepting Aggregation Report or Chart, select from date, to date from time, to time, machine no, part code, process code combos will be populated based on the selected dates, the user is allowed to select the machine no, part code, process code and click on Ok command button. It will launch the Job selection screen based on the part, process, machine selected by the user and display the following details i.e. Job No, Machine, Part, Process, and Status: - whether it is current job or History Job. The user can select the Job by selecting the row.  Click on Ok it will display all parameter on parameter selection screen. Select the frequency from combo as - Daily or Weekly or Monthly.

If the user selects daily then average of the reading for the day for the parameter is displayed in the report for the specified criteria. Suppose the selected date is 1st July 2005 to 15th July 2005 Date column will be displayed as 01-Jul-2005, 02-Jul-2005, ----------, 15-Jul-2005 in Aggregation report.

If the user selects weekly then average of the reading for the week for the parameter is displayed in the report for the specified criteria. In case of weekly the user has to select dates such that it would be for at least 2 weeks and from date selected should be a Monday. Suppose if the user selects from date as 4th July 2005 and to date as

19th July 2005 then the weeks would be 4th July 2005 to 10th July 2005,

11th July 2005 to 17th July 2005, 18th July 2005 to 24th July 2005

If the user selects monthly then average of the reading for the month for the parameter is displayed in the report for the specified criteria. In case of monthly the user has to select dates such that it would be for at least 2 months and from date selected should be 1st day of the month. Suppose if the user selects from date as

1st July 2005 and to date as 8th September 2005 then the months would be

1st July 2005 to 31st July 2005,

1st Aug 2005 to 31st Aug 2005,

1st Sep 2005 to 30th Sep 2005

Click on Ok it will display all selected parameter in the report i.e. on each sheet maximum 15 parameters can be display. If the user does not select any parameter and click on Ok then all the parameters will be displayed in the report.


Aggregation chart

Chart will be display as X chart for the selected parameters only when the user selects the Aggregation Chart Report. When the user clicks on Ok the first parameter that is selected is displayed as the first chart and all the selected parameters are shown as the sub menu of XChart

When frequency is daily means take the daily average of each parameter for XChart.

For E.g. If user selects the date as 1-Jul-2005 to 15-Jul-2005.  Total 15 readings will be display in the chart of each parameter if data is available for daily.

When frequency is Weekly means take the Weekly average of each parameter.

E.g. If user selects the date as 1-Jul-2005 to 31-Jul-2005.

Total 4 reading will be display in the chart of each parameter if data is available for weekly.

When frequency is Monthly means take the Monthly average of each parameter.

E.g. If user selects the date as 1-Jun-2005 to 30-Nov-2005.

Total 6 readings will be displayed in the chart of each parameter if data is available for Monthly.


Wrapping X chart

X-Chart with wrap facility will be displayed only if e.g. Bilcare flag is true. If X-Chart with wrap is selected then two menus All Points and Scroll under view menu will be enabled. If Scroll is selected then Next and Previous menu will be enabled. If All Points is selected then Next and Previous menu will be disabled. If all points is selected then all points will be plotted. If Scroll is selected then only First 90 point will be plotted out of the total points. The remaining points can be plotted using Next and Previous menu. If Scroll is selected and No of points to be plotted is less than 90 then all the points will be plotted and Next and Previous menus will be disabled.

The X chart is a graphical representation of individual values in a sample. The canvas is divided into 3 regions by 2 benchmark lines.

-	Header region

-	Drawing region

-	Footer region


Licensing of PROQMS System.doc
Licensing of PROQMS System

After double clicking on shortcut of ProQMS, Licensing screen will get launched.

Licensing screen provides the facility for creation of file which will be useful for DSS to create for permanent or extended licensing. Licensing screen will not get display after the permanent registration.

License screen contains three buttons.

•	Generate License File – After user click on ‘Generate License File’ button, DSSLicense.inf file will create in application path. Customer has to send this file without modification to DSS for permanent registration

As per customer need, DSS will make the license file for extension of expiry or Permanent license.

•	Register – Product will get register i.e. depending upon the customer requirement product expiry date increases or after purchasing the product, product get converted into legal i.e Permanent license copy.

User can select the file, License.inf by clicking on…. Button for registering the product or the Extension of the Expiry Date also

Authorize license copy of ProQMS system will get install on the system otherwise product gets expired after 30 days or expiry date.

•	Continue / Exit - If the Product is type of demo version Continue button will get display and when the product is expired then Exit button will get display. After click on Continue button Licensing screen will get unloaded & Login screen will get launch.

After product gets expired, licensing screen will get launch with Exit button & after user click on Exit button application get unloaded


Dashboard_Master

Use this option to define various plants/Divisions/Units/cells.

Using Tree control following hierarchy will be created.

•	Plants

•	Divisions

•	Units

•	Cells

Select Configuration/Dashboard Master to add plants. Click on Add, display in right hand side is Plant description. Select the Plant to add the Division [Module]. Select the Division [Module] to add the Unit. Select the Unit to add the Cell [i.e. Location]. Display List Box in the RHS Side for the selection of Location [Cell]

•	User cannot delete any node if it is referred in the User Detail.

•	If user tries to delete Plant, which has defined Divisions, Units and Cells and if it is not referred in the User Detail ask for the confirmation for Deletion. If user Press 'Yes' display message 'There are divisions defined! Are you sure you want to delete this record?’ If user press 'Yes' selected Plant will get deleted along with Division, Units and Cells.

•	For Modifying Plants or Divisions or Units, user can select and click on Modify. Text box of Plants Description will get enabled so that user can modify. After modifying, user can click on Save to modified the record.

•	If Cell/Location is assigned to user and then user try to modify the Location/Cell display the message as 'Cannot Modify, Record exists in Assign Dashboard Level To User'.

•	If Cell/Location is not assigned to user and user try to modify the Location/Cell and Cells are available for assigning to Units, display the other cells with selected cells in RHS side. User try to select multiple cell then display the message 'Multiple selection is not allowed in modify mode'. User has to uncheck the selected or earlier one and select the other cell to modify the Cell and click on save to modify the record.

•	If user clicks on add for adding the Cell/Locations and No cells are present to add in unit then system should display the message as 'No location left to add'.

•	Plants, Divisions, Units and Cell/Location cannot be same. Same Plant description cannot be defined as Units or Divisions.


Assign_Dashboard_Level

Use this option to assign the dashboard levels to users.

Select Configuration/Assign Dashboard Level option. User selection is done through the  Display combo Box. Assign the levels to the user through Display Tree control. When user selects the parent node then automatically child node should get selected. If Child node is selected then automatically Parent node should get selected.

User can assign i.e. add dashboard level to users, modify the Dashboard levels and can be deleted the levels of user.

In View mode, tree will display without check box so that user can see the complete tree by click on ‘+’ or ‘-‘.

In Add, Modify mode, tree will display with check box so that user select or deselect the tree node.

In Modify mode, new tree i.e complete dashboard will get display of which those are assign to user get checked & rest of them are unchecked.


Overview_of_Dashboard

Select the option Configuration/Dashboard Master to define various plants, divisions, units and Cells.

Select the option Configuration/Assign Dashboard levels to assign the dashboard levels to users.

Login

Dashboard Navigation

Dashboard Cp,Cpk screen

Control Chart (OCX)


Login

It will provide login details of web-based dashboard. It prevents the unknown user to login in the Dashboard site.

Enter User Name and Password with Login button.

•	If User Name or password is wrong then user can see the message 'The username or password is incorrect. Please try again.’

•	If user Name and password is correct and user has not assigned the dashboard level then user can see the message 'User has not defined the dashboard level'.

•	If user is not active then user can see the message "User is not valid as active indicator is not checked in user screen"

•	If user password is expired then user can see the message "Your password is expired. Contact System Administrator"

When user entered valid user name and password then display the screen of the dashboard level for the logged in user.


Dashboard_Navigation

It provides dashboard navigation for Plant, Division, Unit, and Cell/Location page.

After the successful login user can see his dashboard on the page. Color will be display as per the control limits and Cpk value.

•	Green  - In control and Capable

•	Yellow - Not in Control but capable

•	Orange - In Control and Not Capable

•	Red - Not in Control and Not Capable

If user has assigned different locations from different Plants then user can see the Different Plants on the first screen. When user clicked on Plants then immediate user can see the Locations/Cells which are assigned for user. When user click on Locations/Cells then user can see all the parameters i.e. all the jobs which are assigned for that locations.  i.e. Job No, Machine No, Part No, Parameter, Process Status, Cp and Cpk.

When user clicks on Process status column then Control Charts will be display in new window. i.e. Histogram, Statistical Analysis, X Bar R chart and readings in the grid.

•	If one of the parameter is Red from selected location then color of the Cell/Location is Red and the Plants color will also Red. Priority of the color is Red, Orange, yellow and Green.

•	If one of the Parameter is Red then color for the cell is Red.

•	If one of the parameter is not red and one of the parameter is Orange then color for the cell is Orange.

•	If one of the parameter is not red, not orange and one of the parameter is yellow then color for the cell is Yellow.

•	If one of the parameter is not red, not orange, not yellow and color of all parameter is Green then color for the cell is Green.

•	If one of the parameter is Red from one cell then that Cell's color will be Red. The Cell is under in which Unit/Division/Plant will have also color Red.

User is on Dashboard Page i.e. Cp/Cpk Page. User has gone to this page by selecting Plant, unit and cell then user can see the link button options at the top i.e. Home -> Plant Name -> Unit Name -> Cell Name.

Cell Name is disabled from link button options. Home -> Plant Name -> Unit Name are enabled and user can click those link buttons. So that user can go directly to the page by clicking link button option.

Running Line –

When user unselected the Running Line in Location Master then color of the cell button will be display as white.

Cp/Cpk based on QAP –

Process Status, Cp, Cpk and Pp, Ppk value will be calculated and display based on the Last Sample No configured in QAP.  If user entered zero then these values will be calculated for all the samples.

Color coding of the process status of the parameter will not be considered when Line is not running and if data is not dumped for more than or equal to 1 day.


Machine_Event

Use this option to create machine event for selected machine, event date, event time & jobs for selected machine.

Select Monitoring/Machine Event from Main Menu to display the Machine Event master.

•	On Add operation, all Machine No, Machine Event will get populated in respective combo box. All Job for machine will filled in a grid.

•	On Modify operation, if record for selected machine no is not available in event remark then user can modify the record for event date, event time, and event code.

•	On Save operation, record for selected machine no will get saved. Selection of job no will be the optional for machine event.

•	On Delete operation, if record is not available in event remark then selected record will get deleted.

For selected machine no have more than one record in machine event then combo box for event date/time/event code will get filled with respective record so user can navigate the record for same machine no.


Export Data of Component Number Report

Use this option to generate an Export Data of Component Number Report that will display the process wise parameter values for the selected component number.

When component number flag is true then click on Report -> Export Data of Component Number Report menu item. A screen for accepting required information will be launched. Select the Component Number, Date, Shift, Part Number & Station Number and then click on Ok button to confirm the selection and proceed with the generation of reports.

Click on Cancel to leave this dialog without making any modifications or to cancel the operation.

Report will display company name and report name in the report title. This report will display the selected Component number, Part Number, Date, Station Number and the process wise parameter values for the selected component number.

It displays Machining-tracking number instead of Shift in case of g_breaksIndia flag is true.


Date Wise Export Data of Component Number Report

Use this option to generate a Date-Wise Export Data of Component Number Report that will display the date wise component number with parameter values for the selected period, part number and process.

When component number flag is true then Click on Report -> Date-Wise Export Data of Component Number Report menu item. A screen for accepting required information will be launched. Select From Date, To Date, Station No. & Part Number and then click on Ok button to confirm the selection and proceed with the generation of reports.

Click on Cancel to leave this dialog without making any modifications or to cancel the operation.

Report will display company name and report name in the report title. This report will display the selected Station number, Part Number, Date & Process and the date wise Component Number with parameter values for the selected period.

If Part Number has three processes, i.e. Component number has gone into three processes then data will be displayed in three different tab. i.e. each process has different tab.

It displays Machining-tracking number instead of Shift in case of g_breaksIndia flag is true.


The Component Tab

Enter Date, Shift, and component number and for collecting reading of selected Parameters for different jobs in the Component tab.  Data can be collected in auto or Manual mode.

While launching measurement screen if (one of the Parameter) reading is incomplete for component number display cycle is incomplete. While closing measurement screen if (one of the Parameter) reading is incomplete for component number display cycle is incomplete. Populate the reading as per Company Setting in Component Tab.

If reading is beyond specification limit then display background color of the reading is Red.

Uniqueness for Date + shift + Component Number for selected jobs will be checked.

Reading Date should be greater than or equal to Last Reading Date.

To clear the grid and to display last component number data in the 1st row, press function key F5.User can enter reading for any parameter of the component Number in the grid.

User can select more than one job.

While launching measurement screen user selects more than one job, check same component number is present in all jobs. If component number is not present in all selected jobs then display message ‘Different jobs are selected as same component number is not present.’ And measurement screen will not get launched.

Request Data button is not displayed in Manual Mode and it gets displayed in Auto mode.

When user enters component number in the grid then Request Data button should get enabled. When user clicks on Request data then data should get dumped into the grid as per the parameter of Instrument address and Request Data button should get disabled.

After capturing reading for all parameter then next row should get added in the grid.

Request should stop after all parameters readings are stored.  Request should happen after 5 second if some of the parameters reading are pending.

In auto mode user cannot edit the reading.

Component No Tab will be displayed only when component number Flag is true. In x-chart when user moves the mouse pointer on reading display Component number along with reading.

Following validation or steps will be done when g_BreakIndia flag is true.

Grid contains following columns Date, Component No, Machining Tracking Number and two parameters i.e. Top and Bottom and last column is position.

Date, Component No and Machining tracking Number will be entered by user. Date+Component Number is unique. Component will be checked at 4th positions.

User has to check component serially i.e. position-wise. 1st, 2nd, 3rd & 4th.

When user checks the component at position 1 then in component tab displays the value of Top and Bottom in the respective column of the grid and in the position column value will display as 1. In reading tab display the value of Top and bottom in Top1 and Botom1 parameter.

When user checks the component at position 2 then in component tab displays the value of Top and Bottom in the respective column of the grid and in the position column value will display as 2.   In reading tab display the value of Top and bottom in Top2 and Bottom 2 parameter.

When user checks the component at position 3 then in component tab displays the value of Top and Bottom in the respective column of the grid and in the position column value will display as 3.   In reading tab display the value of Top and bottom in Top3 and Botom3 parameter.

When user checks the component at position 4 then in component tab display the value of Top and Bottom in the respective column of the grid and in the position column value will display as 4.  In reading tab display the value of Top and bottom in Top4 and Botom4 parameter.

After saving the value of parameter Top4 and Botom4, system will calculate the value of Top parameter is (Top1+Top2+Top3+Top4)/4 and the value of Bottom parameter is (Botom1+Botom2+Botom3+Botom4)/4

After calculating the value of Top and Bottom, in component grid display the calculated value in Top and Bottom column of the parameter and display blank in Position column and system will add one row with current date, in date column and cursor should wait on component No. column.

If Component number, machine tracking number or Date is not assigned and user tries to press the switch for collecting data, ignore the reading and put in the log file.

Suppose user has checked the component number at 1st position and user tries to close the measurement screen then system should display the message as Cycle has not completed Do you want to continue? . If user presses No then system will close the measurement screen.

If user press 'Yes' then Measurement screen will not get closed. So that user can continue to check the component.

Suppose user has checked component no. at position 1 and closed the measurement screen. User has selected the job from local monitor as per stated above and launched the measurement screen. System will display the message 'Cycle is not completed' and the value of Top and Bottom will display which was taken earlier and position column will display value as 1. Now user has to check the component at position 2 and cycle will continue.

Display the background color of the cell is depending upon the reading.

If reading is beyond the specification then display the color as Red.

If reading is out of control limit and within the Specification limit then background color of the cell is Yellow.

If reading is within control limit then background color of the cell is Green.

As per the company settings configuration, grid will display those many rows in the component grid. System will refresh the grid when rows are equal to the company-setting configuration.

To clear the grid press function keys F5 and display the 1st row value with last component number.

Provide check box to display all parameters in case of auto mode. By default when user tries to launch measurement screen in auto mode display only two parameters and position along with Date, Component No and Machining tracking number when instrument interface is DEWTRT2. If instrument interface is not DEWTRT2 then display all parameters in the component tab.

When user selects all parameters check box, and then system displays all parameters along with Date, component number and machining tracking number. Do not display Position column.

If component number is not assigned then user can do manual entry in the Reading tab.

If component number is not assigned then also user can take reading in auto mode of Reading tab.

In manual mode display all parameters in component grid so that user can do manual entry.

If component number is assigned then user cannot do entry in Reading tab.

If component number is not assigned, sample number and reading serial number is not same for all parameter and user tries to enter the data in component tab display message ‘ Sample Number and Reading serial number is not same for all parameter.

Machining tracking Number columns can be seen only when Breaks India flag is true.

Shift column can be seen only when SClPrefix flag is true.

When Breaks India flag is false and SclPrefix flag is false then in component tab user can see Date, Component Serial Number and all parameters sequentially.

Deletion Facility -

When component Number flag is assigned then deletion facility should be disabled from Measurement screen. If the user press F6 key then the application displays message as ‘Cannot Delete, Component number is assigned’.


Tray Tracking Chart

When g_HeatTreatment flag is true, then in Configuration menu Tray Tracking sub menu will get visible. User selects Tray Date, Tray Time and Parameter Category for displaying Tray tracking chart for variation of parameter category. It will provide the information for Tray Tracking for Variation of Parameter Category Screen.

In this screen, user can select or enter Tray Date, select Tray Time and Parameter Category. Tray Date will get populated from Tray Time Entry screen. When user has selected the Tray Date then system will populate all Tray Time entered for selected date. System has provided facility to select maximum 2 Parameter Category. On selection of parameter category Ok button will get enabled. Cancel button has provided to close the screen.


License

Select File/Maintenance License from the Main Menu to provide the information for No of concurrent user, License Type, No of Days for DSS License Screen and Creation of DSSLicense.Inf file, Registration of Pro-QMS License for Maintenance License.

Maintenance License menu will get visible only for Role ‘INST’.

DSS License Screen –

When license type is either temporary or extended, In Demo screen when user clicks on ‘Generate License File’, System will launch DSS License screen.

When license type is ‘Permanent’ and user wants to upgrade license i.e. concurrent user then user should use ‘Maintenance License’ under File menu.

When license type is either temporary or extended, system will enabled ‘Extended’ or ‘Permanent’ license type otherwise ‘Permanent’ will get enabled. When user enters ‘No of Concurrent user’, ’No of Days’ and select License Type and click on OK button. System will create the DSSlicense.Inf file in the application path and system will open the windows explorer i.e. where the DssLicense.Inf file gets created.

Maintenance License –

When customer wants to send license file to DSS for upgrade concurrent user or extend temporary licensing or permanent then user/customer should click on ‘Generate License File’ button from Maintenance File, system will create the DSSLicense.Inf file. This file should send to DSS.

DSS will send License.Inf to customer as per the DssLicense.Inf file. When customer wants to extend license period or increase number of concurrent user or to do temporary to permanent then customer should use License.inf file. Customer should click on Register button from Maintenance License screen, Registration screen will get display


Database

This screen is used to set the database of your choice for storing the process quality data. This may be done on the above screen, which has the two tabs RDBMS and Connection. On the RDBMS tab, specify the database vendor names from the following list:

DB2

ORACLE

SQL-Server

Sybase

MS-ACCESS

After completing the desired selection click Next to move to the next tab. On the Connection tab, enter the following information related to the database connection that you want to create:

DSN – Data Source Name is a term for the collection of information used to connect your application to a particular ODBC database.

User Name - The user ID which is accessed for providing security to the database.

Password – The password is used to provide database access to an authorized user only.

Server – Server Name

Database – Database Name

Once you have entered the necessary information, click Apply and then click OK which displays the security screen. You may leave this dialog without modification by clicking Cancel.


Company

Use this option to enter information related to the company and make required settings. Click Modify on the toolbar to make changes. The following information is entered on this screen:

Name

Address

City

Zip

Fax

Telephone

Activate Job Level Security – Check this option if you want to enforce authorization checks at the launch of Local Monitoring and Fixture Monitoring screens. This means only authorized users can access these screens.

Activate Trend Setting Globally – Check this option if you want the Trend Settings to be applicable to all machines.

No. Of Points To Be Displayed On Online Charts – Specify the number of samples that should be displayed in the online charts of the measurement screens.

Display / Capture Time to Take Reading– User checks the ‘Display/Capture Time to Take Reading’ if user has not taken the reading for specified sample frequency then ‘Time to take Reading’ Event/Trend will get captured. If user does not checks then ‘Time to take Reading’ Event/Trend will not get captured

When g_Heat Treatment flag is true then frame, which contains Name of Plantscape Server, Archive Path, Average Type and Request Time (In Min.) will get visible.

•	Name of Plantscape Server – Enter the name of Plantscape Server.

•	Archive Path – Enter Archive path (the only field which is optional)

•	Average Type – Select a pre-defined value from drop down list.

•	Request Time – Enter Request Time which is multiples of 5 of Average Type or more than that.

Click Save to save the settings.


Trend Settings

Trend Settings screen is used to set the trends for X Bar R charts in measurement screen.

Check the box against Ppk if you wish to consider it for Trend Settings.

The trend control checks can be enabled for the mean and/or the range charts by clicking the appropriate check box. If a trend control check is enabled, the size of the trend as the number of consecutive points must be specified via the spin box next to the check boxes. Trend control checks provide a way to determine the out of control status of a sample. There are three types of control checks: Points Outside Control Limits, Trend Analysis and Zone Analysis

The Runs Up and Runs Down checks must share the same trend size as to the Runs Greater Than Mean and Runs Less Than Mean Checks.

Error Code Entry – This checkbox is used to enable the display of Corrective Action screen so that the operator can take the corrective action when any trend is raised during data collection.

Points Outside Control Limits – You may check this option for Mean and/or range to raise a trend if the sample just collected lies outside the control limits but within the specification limits.

Middle Third – You may check this option for Mean and/or Range to raise a trend whenever more than two thirds of the mean of the sample just collected and the mean’s/range’s of all previous samples collected are within a one sigma spread about the center line of the Mean/Range chart.

Zone A – You may check this option for Mean chart, to raise a trend if consecutive 2 of 3 samples lie in Zone A+ or above/Zone A- or below. You may check this option for Range chart, to raise a trend if consecutive 2 samples lie in Zone A+ or above, or if consecutive 4 samples lie in Zone A- or below.

Zone B – You may check this option for Mean chart, to raise a trend if consecutive 4 of 5 samples lie in Zone B+ or above/Zone B- or below. You may check this option for Range chart, to raise a trend if consecutive 3 samples lie in Zone B+ or above, or if consecutive 6 samples lie in Zone B- or below.

Zone C – You may check this option for Mean chart, to raise a trend if consecutive 8 samples lie in Zone C+ or above/ Zone C- or below.  You may check this option for Range chart, to raise a trend if consecutive 10 samples lie in Zone C- or below, or if consecutive 7 samples lie in Zone C+ or above.

Up – You may check this option for Mean/Range chart to raise a trend if the mean/range is increasing for consecutive no of samples as specified in the Trend Size.

Down – You may check this option for Mean/Range chart to raise a trend if the mean/range is decreasing for consecutive no of samples as specified in the Trend Size.

Greater Than – You may check this option for Mean/Range chart to raise a trend if the mean/range of the current sample and all the previous consecutive no of samples as specified in the Trend Size, lie above the center line.

Less Than – You may check this option for Mean/Range chart to raise a trend if the mean/range is of the current sample and all the previous consecutive no of samples as specified in the Trend Size, lie below the center line.

For Up, Down, Greater Than and Less Than options two levels viz. Level 1 and Level 2 are present.


Points Outside Control Limits

This control check is violated for the mean chart whenever the mean of the sample just collected falls above the current upper control limit for the mean chart or falls below the current lower control limit for the mean chart.

This control check is violated for the range chart whenever the range of the sample just collected falls above the current upper control limit for the range chart or falls below the current lower control limit for the range chart.


Trend Analysis

Trend analysis checks for the following trends:

Runs Up

The Runs Up trend control check is violated for the mean chart whenever the mean of the sample just collected is greater than mean of the previous sample. Size of the trend is specified in the spin box. If size of the trend is 3, then if mean of the last three consecutive samples that is up then trends Runs Up will get raised for mean chart.

The Runs Up trend control check is violated for the range chart whenever the range of the sample just collected greater than range of the previous sample. Size of the trend is specified in the spin box. If size of the trend is 3, then if range of last three consecutive samples is up then trends Runs Up will get raised for range chart.

Runs Down

The Runs Down trend control check is violated for the mean chart whenever the mean of the samples just collected less than mean of the previous sample. Size of the trend is specified in the spin box. If size of the trend is 3, if last three consecutive samples are down then trends Runs Down will get raised for mean chart.

The Runs Down trend control check is violated for the range chart whenever the range of the samples just collected less than range of the previous sample. Size of the trend is specified in the spin box. If size of the trend is 3, if last three consecutive samples are down then trends Runs Down will get raised for range chart.

Runs Greater Than

The Runs Greater Than mean trend control check is violated for the mean chart whenever the mean of the sample just collected, and the mean of the previous samples, all lie above the current center line of the mean chart. Size of the trend is specified in the spin box. If size of the trend is 3, if last three consecutive samples are lie above the current centerline of the mean chart then trends Runs Greater than Mean will get raised for mean chart.

The Runs Greater Than Mean trend control check is violated for the range chart whenever the range of the sample just collected, and the range of the previous samples, all lie above the current centerline of the range chart. Size of the trend is specified in the spin box. If size of he trend is 3, if last three consecutive samples are lie above the current center line of the range chart then trends Runs Greater Than Range will get raised for range chart.

Runs Less Than

The Runs Less Than mean trend control check is violated for the mean chart whenever the mean of the sample just collected, and the mean of the previous samples, all lie below the current center line of the mean chart. Size of the trend is specified in the spin box. If size of the trend is 3, if last three consecutive samples are lie below the current centerline of the mean chart then trends Runs Less Than Mean will get raised for mean chart.

The Runs Less Than range trend control check is violated for the range chart whenever the range of the sample just collected, and the range of the previous samples, all lie below the current centerline of the range chart. Size of the trend is specified in the spin box. If size of the trend is 3, if last three consecutive samples are up and all lie below the current centerline of the range chart then trends Runs Less Than Range will get raised for range chart.


Middle Third Rule

The Middle Third control check is violated for the mean chart whenever more than two thirds of the mean of the sample just collected and the means of all previous samples collected are within a one sigma spread about the center line of the mean chart. The Middle Third control check is violated for the range chart whenever more than two thirds of the mean of the sample just collected and the ranges of all previous samples collected are within a one sigma spread about the center line of the range chart. The spread between the current upper and lower control limits of the mean and range chart is 6 sigma wide; therefore the plus and minus one sigma spread about the centerline designates the middle third region of a control chart.


Example for Level 1 & Level 2

Level 1 - Runs Up is checked for mean chart and size of the trend is 3.

Level 2 – For Second level the size of the trend should be greater than the first level of the trend size. If Runs Up is checked for mean chart and size of the trend is entered less than or equal to 3 then it will display the message ' Runs Up and Runs Down should be greater than 3', because in first level size of the trend is 3.

This is valid for all trends like Runs Down, Greater than Less than Mean/Range.  In this application 2 levels are used. Depending upon the selection of levels trends are raised. E.g. In First level Runs Up is checked and size of the trend is 3. In Second level Runs Up is checked and size of the trend is 5.

Following two cases are explained depending upon the above example.

Case - 1

If last three consecutive samples are UP then trend will get raised as  'Runs up violated for mean chart at level 1 for parameter height’; Operator has not taken the corrective action for the same trend. Operator is dumping the reading and the next two samples are also up then trends will be raised as  'Runs up violated for mean chart at level 2 for parameter height' and then the login screen will come. Here only supervisor can login. Operator has to call up supervisor and after successful of supervisor login, it will show the corrective Action screen so here Supervisor has to take the corrective action for the same trend then only operator can continue to take the readings and here the trends will get reset.

Case - 2

If last three consecutive samples are UP then trend will get raised as 'Runs up violated for mean chart at level 1 for parameter height’; Operator has taken the corrective action for the same trend. Then the trends for it will get reset. Operator is dumping the reading and the next two samples are also up then Trends will not be raised as  'Runs up violated for mean chart at level 2 for parameter height' because the operator has already taken the corrective action at first level only.  If the operator has taken the corrective action at first level only then second level trend will not be get raised.

Second level trends will get raised only when operator has not taken the corrective action at level one and the next two consecutive samples are up for mean i.e. depending upon the selection of the trend size.

First level trends have been raised and the operator has not taken the corrective action and the next consecutive sample is not runs up then the trends for up will be get reset.

Above cases are also valid for all the trends like Runs Down, Greater than Mean, Less Than Mean if the option is checked in Trend Settings.


Zone Analysis

As described in the discussion of the Middle Third Rule, the spread between the current control limits of a mean or range chart can be divided into 6 zones each zone being one sigma wide

Zones C are the zones closest to the centerline; zones C+ and C- constitute the middle third region of the control chart. Zones A are the zones closest to the chart control limit. The zone between zone C and zone A comprises of Zone B.  Zone Analysis is based on the Western Electric Zone Analysis method.

Zone A -

Zone A for Mean Chart –

If consecutive 2 of 3 samples lie in Zone A+ or above then trends will get raised as 2 of every 3 samples in zone A+ or above.

If consecutive 2 of 3 samples lie in Zone A- or above then trends will get raised as 2 of every 3 samples in zone A- or below

Zone A for Range Chart –

If consecutive 2 samples lie in Zone A+ then trends will get raised as 2 samples in a row in zone A+ or above

If consecutive 4 samples lie in Zone A- then trends will get raised as 4 samples in a row in zone A- or below

Zone B -

Zone B for Mean Chart –

If consecutive 4 of 5 samples lie in Zone B+ or above then trends will get raised as 4 of every 5 samples in zone B+ or above

If consecutive 4 of 5 samples lie in Zone B- or below then trends will get raised as 4 of every 5 samples in zone B- or below

Zone B for Range Chart –

If consecutive 3 samples lie in Zone B+ or above then trends will get raised as 3 samples in a row in zone B+ or above

If consecutive 6 samples lie in Zone B- or below then trends will get raised as 6 samples in a row in zone B- or below

Zone C -

Zone C for Mean Chart –

If consecutive 8 samples lie in Zone C+ or above then trends will get raised as 8 samples in a row in zone C+ or above

If consecutive 8 samples lie in Zone C- or below then trends will get raised as 8 samples in a row in zone C- or below

Zone C for Range Chart –

If consecutive 10 samples lie in Zone C- or below then trends will get raised as 10 samples in a row in zone C- or below

If consecutive 7 samples lie in Zone C+ or above then trends will get raised as 7 samples in a row in zone C+ or above


Send Message

You can use this screen for sending messages to other machines. For sending a message to a machine, you have to select the Machine, from the Machine No. Drop down list box. The message to be sent should be typed in the Message textbox. For sending the message you have to click the OK button. Cancel button can be used to close the screen.


Get Message

You can use this screen to view the received messages.  Get Message screen displays the messages that have been sent to the machine. The sender textbox displays the user code of the person who has sent the message. Its adjoining textbox displays the date and time when the message was sent. You can view the previous messages received by using the Top, Prev, Next and Last buttons. You cannot add or modify any message in this screen. You can delete the messages using the Delete button. You are allowed to delete only the messages, which have been received two months previous from the current date.


Departments

Use this option to enter all departments within the organization. Each department is identified by a unique department code.

Click Add to add a new entry. Enter the following details:

Code – The Department code.

Description – The name of the Department.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You cannot delete a department if it is used in the User Screen.


Users

Use this option to enter information about the members of the organization.

Click Add to add a new entry. Enter the following details:

Code – A unique code to identify the user of the application.

Name – The name of the user.

Department Code – The department to which the user belongs. Departments are defined in the Department master.

Role Code – The role assigned to the user. Roles are defined in the Role master.

Employee No – The employee number assigned to the user.

Active Indicator – This indicates if the user is active in the organization. A non-active user is not allowed to log into the application.

Password – The password used to log into the application.

Password Expiry Date – The date till which the user’s password is active. After this date the user cannot login. 7 days prior to the expiry date, a message is displayed that the password is about to expire.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. A user cannot be deleted if he is logged in.


Supervisor

Use this option to define Supervisors.

Click Add to add a new entry. Enter the following details:

Code – The Supervisor code. Supervisors are users defined in the User master.

Color – Select the required color. This color code is helpful at the time of report generation.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. Modification and deletion is allowed only if the supervisor is not used in the Production screen.


Role

Use this option to create different roles that are required for the organization.

Click Add to add a new entry. Enter the following details:

Role Code – The Role code.

Description – The description of the role.

Active Indicator – This indicates if the role is currently active in the organization. If the active indicator is not checked then users cannot be assigned this role

Functionality and Access Rights – The various functionalities i.e. screens of the application are listed. You may define the access rights for all the screens. By default the access rights for each screen is None. A user has access to the screens of the application based on these access rights.

Access Rights    Description

None                     No access is available to the screen

Read Only            You can only view the screen

Modify                  You can only modify the contents

Full                        You can add, modify or delete the contents

Click Modify to modify details. If the Active Indicator is checked then you can un-check it only if no users exist for the role. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a Role only if no users exist for that role.


Parts

Use this option to define the manufacturing parts.

Click Add to add a new entry. Enter the following details:

Code – The Part code.

Name – The name of the Part.

Number – The Drawing number.

Issue Index – The issue index of the Part.

Specification – Specification details.

Raw Material Cost Per Unit – The cost of raw material per unit.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a part only if the Standard Quality Assurance Plan is not defined for the part.


Process

Use this option to define various processes for the manufacturing parts.

Click Add to add a new entry. Enter the following details:

Code – The Process code.

Description – The description of the Process.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a process only if it is not used in defining the Standard Quality Assurance Plan for a part.


Part Parameter

Use this option to define parameters for which measurement data will be captured for analysis of the part and process.

Click Add to add a new entry. Enter the following details:

Code – The Parameter code.

Description – The description of the Parameter.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a parameter if it is not used in defining the Standard Quality Assurance Plan for a part or for fixture settings.


Parameter

Use this option to define the various parameters for the Tools that have to be monitored. This master is used in the Tool Life Monitoring Module.

Click Add to add a new entry. Enter the following details:

Type – Select the Tool Parameters as a type from the drop down list.

Code – The Parameter code.

Description – The description of the Parameter.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a parameter if it is not used in defining a tool type in the Tool Type screen.

Use this option to define the various steps parameters for the instruments that have to be calibrated. Click Add to add a new entry. Enter the following details:

Type – Select the Gauge Calibration Steps as a type from the drop down list.

Code – The Step code.

Description – The description of the Steps.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete Steps if it is not used in defining an Instrument calibration screen


Location

Use this option to define locations which will be used in defining the Machine master and Instrument master.

Click Add to add a new entry. Enter the following details:

Code – The Location code.

Description – The description of the Location.

Running Line check box - By default checkbox should be checked.

This will be used in web dashboard to know whether selected location/cell is in running state or not, if running line unselected then back color of that location/cell display in white color.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a location only if it is not referenced in the Machine master or Instrument master.


Machine Type

Use this option to define various machine types.

Click Add to add a new entry. Enter the following details:

Type – The type of machine.

Description – The description of the Machine Type.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a machine type only if it is not used in the Machine master.


Machine

Use this option to enter details of the different Machines.

Click Add to add a new entry. Enter the following details:

Machine Number – The number identifying the machine.

Machine Description – The description of the Machine.

Location Code – The location code where the machine is.

Location Description – The name of the location.

Rate Per Hour – The hourly rate of production.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a machine only if a Job has not been created for it.


Fixture

A set of Gauges bundled together to evaluate a product or on an item during the process manufacturing is called a FIXTURE. Each gauge attached to a fixture is individually called as a PROBE. Fixture is used to record the readings for various parameters of a part in a single go. This will help the user save his time and energy in taking individual readings one at a time.

In this dialog box various fields have to be added in order to add information for fixtures. To add a Fixture, click on the Add button.

Fixture Code – You have to specify a code in the drop down list box for the Fixture that has to be defined.

Fixture Name – Enter the name of the Fixture.

Manufacturer – You may enter the name of the manufacturer. This field is not mandatory.

Calibration Date – Specify the date when the Fixture should be calibrated.

Interval Time – Specify the interval for receiving the calibration date reminder messages. Calibration Date and Interval Time are used to popup messages on the launch of the Fixture Monitoring screen to notify that the fixture is due for calibration. Depending upon the interval specified, e.g. if the interval time is 10 then, 10 days before the Calibration Date, messages shall be displayed to you on the launch of the Fixture Monitoring.

Location Code – Specify the location where the fixture is situated.

Specifications – You have to specify the specifications of the Fixture.

Fixture Type – Select a fixture type. Fixture Type can be single or multiple. If the fixture type is Single, then single switch will be used for dumping the readings in Measurement screen for all parameters. If the fixture type is multiple then multiple switches i.e. for each parameter a switch is provided.

Click on Modify button to modify the fixture details except for the Fixture Code. To delete a fixture click on Delete button. You can delete a fixture only if Fixture Settings are not defined for selected fixture.


Fixture Settings

Fixture Settings is for defining parameters that can be measured on this fixture and define probes connected to fixture. To add a parameter for the Fixture, click on the Parameter tab and then click on the Add button. Select the Fixture from the Fixture Code drop down list, and the parameter to be linked from the Parameter Code drop down list. Click the Save button to save the record.

To add a probe for a Fixture, click on the Probe tab, and then click on the Add button. Select the Fixture from the Fixture Code drop down list. Add the Probe No. in the text box provided, and select the range for the probe, from the Range drop down list. The probe no’s can be defined from 1 to 16 only.


Instrument Type

Use this option to access details of the types of instruments, their interface and port setting details.

Following are the fields giving details related to Instrument Types:

Code – The Instrument Type code

Description – The description of the Instrument Type

Interface – The interface for the instrument type. The interface codes are defined in the Interface master.

Enter the following fields for serial port setting:

Baud Rate

Parity

No. Of Data Bits

No. Of Stop Bits

Click Add to add a new entry. Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete an instrument type only if it is not referenced in the  Instrument master.


Instruments

Use this option to access information related to Instruments.

Click Add to add a new entry. Enter the following details:

Code – The Instrument code.

Description – The description of the Instrument.

Type – The type of instrument. The instrument type may have serial port or parallel port interface. The instrument types are defined in the Instrument Type master.

Location Code – The location of the instrument on the production floor. The location codes are defined in the Location master.

Responsible For Calibration –The person responsible for calibration of the machine. Such persons are defined in the User master.

   Calibration Frequency (in days) - Enter calibration frequency in days that user want to calibrate & maintain the

    history.

Calibration Due Date – The date on which the instrument is due for calibration. The current date is displayed by default. It will get calculated as per the Calibration frequency.

Least Count  – The least count of the instrument.

Channel No. – This must be entered if the instrument type entered has parallel port interface. This is the exact Channel No. to which the instrument is connected. Select it from the drop down list which contains numbers from 1 to 16. The interface code for a specific instrument is based on the instrument type. The number of channels for an interface code are specified on the Instrument Interface master. The channel no. cannot be greater than the number of channels specified for that interface code.

Ack Channel No. – This is the Acknowledgement Channel No. to which the physical panel is connected. Select it from the drop down list which contains numbers from 1 to 16.

Port No. - This is the actual Port No. to which the instrument is connected. Click Find Port Nos. to display the Find Parallel Port Screen which shows all the parallel ports on the machine. Select the required record from the grid. This is displayed in the Port No. field.

If the instrument type entered has serial port interface then the following fields must be entered.

Baud Rate

Parity

No Of Data Bits

No Of Stop Bits

The above fields are displayed from the Instrument Type master based on the instrument type code entered. You can change them if required.

   Display Cpk –

If DisplayCpk checkbox is true, Cpk Port No combo box will get enable otherwise disable.

If Instrument type has parallel port interface and display Cpk is Checked then Baud Rate, Parity, No of Data Bits, No of Stop Bits will get enable otherwise disable.

When instrument is type of serial port then same port or different port will be used for sending Cpk value. When instrument is type of Parallel port then separate serial port needs to be used for sending the Cpk value

Click Modify to modify instrument details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete instrument details. You can delete an instrument only if it is not referenced in a Job or in any mapping screen for MSA.

When Gauge Management flag is true then only user can see the following fields.

History Card No - History card number of the Instrument.

Gauge Range - Range of the Gauge

Make - Make of the Instrument

GRR Study Date - Study Date of Gauge R & R. This value will be update from the GRR Study.

GRR value - Gauge R & R value. This value will be update from the GRR Study.

GRR Frequency - Frequency of the Gauge R & R

GRR Due Date - Due Date of GRR

Acceptance Criteria - Acceptance Criteria of the Instrument e.g. - Go + / - 0.002 & No-go + / - 0.003 mm

Gauge Drawing No. - Drawing Number of the Gauge e.g. - M 5 249 8 1019 - P 000: 14

Remarks - Remarks of the Gauge

[Description-Part No-Dimensions to be measured]

In Use - Status of the Instrument.

When Gauge calibration is done then user cannot change the Calibration Frequency. When Gauge R & R is done then user cannot change the GRR Frequency. When user try to add new instrument and user entered Instrument code or Description and press function key f5 user can see the frame with Combo of Instrument Code: Description with OK and Cancel Button. When user selects the Instrument from the combo and clicked on Ok then software will populate i.e. copy all the fields of selected instrument to current instrument so that user can make the changes wherever is required and press save button from toolbar to save the record. If user presses cancel then nothing will get populated.

Listing of Instruments –

Gauge Management Flag is true. Instrument screen is Active and user press F6 key then the information of Instrument is exported in the Excel. If Instrument is 'Not In use' then Instrument number will be display in Red color else it will be in back color.  If GRR due Date is less than current date then GRR Due date will be display in Red color.If Calibration due Date is less than current date then Calibration Due date will be display in Red color.


Country

Use this option to define various countries.

Click Add to add a new entry. Enter the following details:

Code – The Country code.

Name – The name of the Country.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a country only if it is not used in the Customer master.


Customers

Use this option to enter details of the different customers.

Click Add to add a new entry. Enter the following details:

Code – The Customer code.

Name – The name of the Customer.

Enter the following additional information about the Customer:

Address

City

Zip

State

Region Name

Country

Country Name

Telephone No.

Facsimile No.

Web Address

Email Address

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a customer only if that code is not used in the Customer Part master


Customer Part

Use this option to maintain the Part Code used by the Customer for a part defined in the Part master. The Customer and Part relationship is used for the Work Order analysis report.

Click Add to add a new entry. Enter the following details:

Code – The Customer code.

Name – The name of the Customer.

Part – The Part Code defined in the Part master.

Description – The description of the part.

Customer Part Number – The code used by the customer to identify the part.

Catalog Code – The catalog code of the part.

Drawing File – The drawing file of the part.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record.


Part Machine

This screen contains information from the Part Master and Machine Master. This is used most frequently at the time of generation of reports. You can then gauge the performance of the part and the machine and the capacity of materials it produces per hour.

Click Add to add a new entry. Enter the following details:

Part Code – The Part code.

Part Description – The description of the part.

Machine Number – The Machine number.

Machine Description – The description of the machine.

Type – The type of machine.

Production Capacity Per Hour – The capacity of material the machine produces per hour.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You cannot delete the Part-Machine relationship if a Job exists for it.


Unit of Measurement

Use this option to enter the different Units of Measurement.

Click Add to add a new entry. Enter the following details:

Code – The Unit of Measurement code.

Description – The description of the Unit of Measurement.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a unit of measurement only if it is not used in the Standard Quality Assurance Plan for defining of a parameter.


Root Cause

Use this option to enter Root Causes which are used in theCorrective Action screen.

Click Add to add a new entry. Enter the following details:

Code – The Root Cause code.

Root Cause – The description of the Root Cause.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a root cause if is not used in Corrective Action screen.


Root Cause Detail

Use this option to define sub causes for root causes defined in the Root Cause Master. This master is used in the Tool Life Monitoring Module.

The Root Cause Detail screen includes the description of the Root Cause code as well as detailed information by providing the Sub Cause associated with it.

The Root Cause codes defined in the Root Cause Master are displayed in the Root Cause drop down list box. Select the required code.

Click Add to add a sub cause. Enter the following details:

Sub Cause – The Sub Cause code.

Description – The description of the Sub Cause.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record.


Shifts

Use this option to enter details of the shifts in which users of the system log on.

Click Add to add a new entry. Enter the following details:

Code – The Shift code.

Description – The description of the Shift.

Start Time – The time the Shift begins.

End Time – The time the Shift ends.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You can delete a shift if it is not used in the Production screen or the Model Shift screen.


Quality Assurance Plan

Quality Assurance Plan – This is planning the quality standards for a part to be manufactured. This may be done at three levels:

The details of each part for which the quality plan will be made and implemented.

The details of each process that can be associated with a specific part.

The details of each parameter that may be associated with a specific part and the process.

  The levels are displayed in a tree structure.

It is expected that you know the following concepts before initiating the quality assurance plan:

Part

Process

Part parameter

Unit of Measurement

Instrument

The Standard QAP  screen has three parts viz. define Part, define Process and define Parameters for the Process.

Defining_Part_in_Standard_QAP

Defining a Process in Standard QAP

Defining Parameters for the Process

Copying Details

Cloning_Details


Copying Details

Use this facility to copy details from one part of the Standard Quality Assurance Plan to another. You may copy information related to parts, processes or parameters. This will prove useful in case of similar items. The Standard QAP can be defined in a shorter time.

Select an item from the tree structure defining the Standard QAP. Use the right click button of the mouse. Select Copy. Then select the appropriate part or process to which it is to be copied. Right click the mouse once more. Select Paste. The details get copied. You may make changes as required.

Cloning Details

Cloning facility can be carried out at all levels that are Part, Process, and Parameter level.

If the user selects the Part/Process/Parameter and right clicks, clone menu is displayed to the user. If the user clicks on clone menu option a new screen with the title Select Part/Process/Parameter is displayed to the user. User can select one or more Part/Process/Parameter and click on OK Button. The Part/Process/Parameters that are selected will have the same specification of the Part/Process Parameters that was selected in Standard QAP screen. Cloning will be done only within Part, Process and Parameter.


Defining a Process in Standard QAP

For creating a new process and to associate it with the part, select part for which process to associated and click on Add button then Process screen will be displayed  .you may select a process from the dropdown list. On selection of process logged in user will shown in prepared by field. You may then click on the Save button to save the record. All processes defined for that part will get be added to tree under selected part.


Defining Parameters for the Process

The process quality and the behavior are determined by monitoring the values of the parameters that influence the quality of the part being manufactured. These may be set on the parameter screen. For adding parameter, select process and then, click on Add.  Parameter screen will show tab sheet related to parameter, where in details can be entered and saved.

Then you may click on the Parameter Code dropdown list to select a parameter code, and select Unit Of Measurement that will be used for measuring from UOM Code dropdown list. You may then select the type of parameter, Attributive or Variable, from the Parameter Type group box. Similarly, the category, Optional and Critical may be decided and selected from the Parameter Category group box.

Formula field in the StdQAp should use the parameters if required, which are defined under the selected Part and the Process. User should not define – in the parameter code when that parameter is used in the Formula field.

You also have to enter the following information while defining a Parameter.

Sampling

Data Access

Limits

Charts


Sampling

You may set size of the sample for quality measurement in the Sample Size text box. You may also specify how frequently sample size may be collected in the Sample Frequency text box.

The manufactured parts may undergo either 100% Inspection or you may choose to do Sampling for the measurement of quality. This may be chosen from the Sampling Technique group box. You may select either Sampling or 100% inspection. If Attributive option is selected in the Parameter tab then you have to enter the Subgroup Size. If subgroup size is not fixed, 0 can be entered in Subgroup Size text box

In mode ‘A’ and ‘M’ when the sampling technique is 100% inspection, sample frequency (in min) should be enabled

Field ‘Display Cpk or Ppk value.’ added to know the system to calculate Cpk or Ppk based on the last sample numbers, if user enters 0 (zero) then system will calculate the Cpk or Ppk based on all sample. If user put the sample no 20 then system will calculate for last 20 samples.


Data Access

The instrument used for the data access may be set on this tab along with the method used for the reading. You may take the readings automatically, which is a Continuous process, or by Interactively. This may be set in the Reading Sequence group box.

For selected instrument type has instrument interface is ‘ESYA’ then Instrument Address label and text box will get visible otherwise it will be invisible. User can enter the Address of the instrument i.e. . in digit. Instrument Address can not be blank. Software will use this instrument address for collecting the data from the Esya Instrument


Limits

Specification limits, control limits and information related to limits are entered in this page.

Select option from Specification Limits group box.

Both Sided – Parameter considers both LSLLSL_Upper_specification_limit and USLUSL_Upper_specification_limit

Lower – Parameter considers only LSL

Upper – Parameter considers only USL

Select option from Control Limits group box.

Calculate – Select this option if you want the control limits to be calculated by the system.

Specify – Select this option if you want specify the control limits.

If Calculate option is selected then select option from Initial Calculation Of Control Limits group box.

Control Limits can be changed even if readings are taken-

Reading has taken for the selected job and user click on Modify, system check whether logged in user has ‘INST’ role or Not if user has ‘INST’ role then move further otherwise flash a message ‘Cannot modify, User role is not INST’ & then operation stop i.e can’t allow for changes.

If user role is ‘INST’ then Control limits & Init. Calc of Ctrl Limits frame get enabled.

User can modify the control limit only (UCLx, LCLx, UCLr, LCLr)

Use LSL and USL – Select this option if you want the Specification Limits to be considered as the initial control limits.

Calculate using 75% of nominal difference – Select this option to control limits to be calculated on the basis of 75% of the Nominal difference. See also - Formula used for calculation of control limits.

If Both Sided option is selected then all textboxes on this tab will be enabled. Lower option will be always disabled. If Upper option is selected then all textboxes on this tab will be enabled & LSL value will be same as Nominal value, later on if user want to modify the LSL can modify it. Also if user modify the LSL Control limit will change

The No of Samples needed for the Limits Calculations may be set here.  If you want the control limits to be calculated repeatedly then you may check in the Recalculation edit box. Nominal Value and Setting Value is also set here.


Charts

You may set on this tab the type of control charts you would like to draw. Depending on the type of parameters you have set on the Parameter tab. You may select and use the following chart types from the Variable Type Parameters group box.

X bar R chart

X bar S chart

Histogram

Pre-control chart

X chart

X MR chart

Pareto Chart

If Pre-Control Chart is selected then all other options get disabled and Best Sample will be displayed if Lower option has been selected under Limits tab. If any one of the above-mentioned charts is selected then Pre-Control option is disabled. Best Sample field will not be displayed.

Similarly following are the chart types for the Attributive Type Parameters

P chart

nP chart

U chart

C chart

Depending on the Subgroup Size you have set on the Sampling tab, attributive charts will be enabled for selection i.e. For Attributive type of parameter, P chart, nP chart, U chart and C chart can be selected. If Subgroup Size is greater than 0 then all options are available. If Subgroup Size is 0 then only P Chart and U Chart options are enabled. P and nP charts fall under ‘Based on Defectives’ group. While U and C chart fall under ‘Based on Defects’ group. In Charts tab if one/both options under one group is selected then options under the other group will be disabled.


Fixture Mapping

This screen provides you a facility to record the readings for various parameters of a part in a single go using fixtures. All the fields on this screen are mandatory. You may enter the information in the following fields by selecting appropriate values from the drop-down list

Fixture code

Part code

Process code

Parameter code

Sequence no.

Formulae

Master Value

Reading type

Fixture Mapping allows mapping parts defined in Standard QAP. Formulae for parameter can be defined by using probes available in selected fixture. Initially setting value set for Part-Process-Parameter in Standard QAP will be shown in Master Value text box. Master value can be changed before saving. Reading Type can be STATIC, MIN, MAX, AVG, TIR this field decides type of reading that needs to be recorded against parameter.

You can modify only the Formulae, Master Value, Sequence Number and Reading Type for selected Fixture, Part, Process and Parameter. Grid will display details such as Parameter Code, Description, and Sequence No, Formulae, Master Value and Reading Type for only those parameters, which have been already mapped to selected Fixture, Part and Process

For deleting a record, you have to select Fixture Code, Part Code, Process Code and Parameter Code from the drop down lists. If the record is referenced then message will be displayed to the user stating that the record is being referenced in Job.


Work Order

A Work Order is a internal production order document prepared for shop/production floor having details of what is to be produced, and how much is to be produced and when to be produced. Click on the Add button to create a new work order record or you may click on the Modify button to modify an existing work order.

You may click on the Work Order No, which is a mandatory field to enter the work order number. Similarly you may select the part number on which the work order is being created from the Part drop down list box. Select Date for the Work Order. Enter the quantity of the parts to be manufactured in the Target Quantity text box.

You may click on the Save button to save the changes on this screen.


Work Order QAP (Quality Assurance Plan)

The QAP for Work Order is inherited from the Standard QAP. The user may change the QAP for a work order for specific requirements of work order. Work Order QAP of part is created automatically by system at the time of work order creation


Batch Maintenance

This screen gives facility for creating batches for work order.

 For creation of batch click on Add button. Then select work order from Work Order drop down list. Select Work order date from Date drop down list. Then enter Batch Number, Batch Date and Planned Quantity for a batch. Planned Quantity for a batch should be less or equal to Target Quantity of Work Order. Click on Modify button to modify batch details. Click on Delete button to remove the batch. You can the batch if Job is not created for selected batch.


Local Monitoring

Use this screen to access information about all jobs created on the local machine and all parameters of selected jobs. This screen provides details of Readings, Pending Decisions, Pending Corrective Actions and Sorting Analysis.

Part combo is provided above the job grid for the filter of specific jobs of selected Part No. When  the form is launched, by default First part will get selected from the part combo box so that job grid will get filled based on the selection of part. When user select blank from the part combo then all job i.e. different part will get listed in the Job grid.

When windows user flag from Configuration file is true then system should display jobs with station no (Computer Name) + Windows user.

When windows user flag from Configuration file is false then system should display jobs with only station no  Computer Name).

Auto Job Selection Facility

When the form is launched, it should display all the jobs for the local machine. Jobs will display in the descending order of Job No. so that the latest job will appear first in the list.

The user checks the select all check box, all the jobs in the job grid will be checked and the corresponding parameters will be displayed in the parameter grid. If all the jobs are selected in the job grid and select all button is clicked the selected jobs are unchecked and the corresponding jobs parameter are removed from the parameter grid.

If the select all checkbox is checked and all the jobs in the job grid are selected and the user clicks on unselect all check box the jobs get unselected and unselect all is disabled and select all is unchecked and enabled.

If the select all checkbox is checked and all the jobs in the job grid are selected and the user clicks Save Job, then next time when the Local Monitoring screen is launched the user will get all the previously selected jobs automatically

Job Closure

Select the job to be closed. You may select Monitoring|Job Closure from the Main Menu or click Job Close on the toolbar to close the job. System will ask ‘Are you sure you want to close this job’. If user presses ‘Yes’ system will ask ‘Do you want to create a job internally?’ If user presses ‘Yes’ then system will create new job internally. Job Number will be Current date time and other details will be taken from the latest QAP for the selected Part and process of the closed jobs.

If the Work Order Job Combine is being used, on deletion of the last job of a work order, the Work Order gets deleted also.

You cannot close the selected job if:

Critical parameters exist for the selected job and no readings have been taken for them.

Some decisions are pending for the job.

While closing the job from Local Monitor / Global Monitor and creating the Job internally then s/w will ask user 'Do you want to retain the old data in the Latest Job' If user say Yes then software will copy the last reading and sample in the latest Jobs for continuity purpose and control Limit also.


Probe Setting

 Probe Setting interface that shows current readings from probes defined for selected Fixture. Before starting measurements form Fixture it is required that all probes be set to zero .For doing this Probe setting screen is used. In all only 16 probes are allowed to be tested and used. Select fixture code from Fixture Code drop down list .It will show connected probe readings, set the probe value from probe box till screen shows current reading of that probe as zero micron.


Fixture Monitoring

Fixture Monitoring shows jobs created on local machine and for which readings will be captured through fixtures. When readings are to be taken using a fixture, it is essential to calibrate the probes. There are two very important features of fixtures,

Mastering

Measure

This screen shows 2 grids, first grid displays all the jobs created for which the monitoring may be done and second grid shows Fixture associated to that job. You may select a job by clicking a row in this grid. Then click on Mastering to launch the Mastering screen. When the mastering is done you may close the form and start collecting the readings or click on Measure button for collecting readings.see capturing data using fixture for further information.


Global Jobs

Global Jobs shows the same set of information as Local Monitoring but global shows all the jobs irrespective of the workstation. You may select a job from the upper gird on the Global Jobs screen and then select a parameter for which data is being collected.  Click on the Global Monitoring button to launch Global Monitoring screen.

The Global Jobs screen displays the Parameter Readings, Pending Decisions and Sorting Analysis for decisions taken similar to Local Monitoring except for the measurement provision.

Auto Job Selection Facility

When the form is launched, it should display all the jobs for the local machine. Jobs will display in the descending order of Job No. so that the latest job will appear first in the list.

The user checks the select all check box, all the jobs in the job grid will be checked and the corresponding parameters will be displayed in the parameter grid. If all the jobs are selected in the job grid and select all button is clicked the selected jobs are unchecked and the corresponding jobs parameter are removed from the parameter grid.

If the select all checkbox is checked and all the jobs in the job grid are selected and the user clicks on unselect all check box the jobs get unselected and unselect all is disabled and select all is unchecked and enabled.

If the select all checkbox is checked and all the jobs in the job grid are selected and the user clicks Save Job, then next time when the Local Monitoring screen is launched the user will get all the previously selected jobs automatically.

Job Closure

Select the job to be closed. You may select Monitoring|Job Closure from the Main Menu or click Job Close on the toolbar to close the job. System will ask ‘Are you sure you want to close this job’. If user presses ‘Yes’ system will ask ‘Do you want to create a job internally?’ If user presses ‘Yes’ then system will create new job internally. Job Number will be Current date time and other details will be taken from the latest QAP for the selected Part and process of the closed jobs.

If the Work Order Job Combine is being used, on deletion of the last job of a work order, the Work Order gets deleted also.

You cannot close the selected job if:

Critical parameters exist for the selected job and no readings have been taken for them.

Some decisions are pending for the job.


Gauge Repeatability & Reproducibility

Gauge R&R, which stands for Gauge Repeatability and Reproducibility, is a statistical tool that measures the amount of variation in the measurement system arising from the measurement device and the people taking the measurement.
"Gauge R&R is intended to be a study to measure the measurement error in measurement systems."

Repeatability

Gauge Repeatability is the variation in the measurements obtained with one gauge when used several times by one operator while measuring the identical characteristic on the same part.

Two sources of repeatability error in the measurement system are:

1. Variation in measurements due to the gauge itself.

2. Positional variation of the part in the gauge.

 Repeatability is thus also called the Equipment Variation (EV).

Reproducibility

Gauge Reproducibility is the variation in the average of measurements made by different operators using the same gauge when measuring identical characteristic on the same part.

Reproducibility error catches the variation due to operators. It is also called the Appraiser Variation (AV).

Study to find Gauge Repeatability & Reproducibility is divided into three parts  –  GRR Mapping,  GRR Measurement and GRR Data Analysis.


Part- Parameter Mapping

This screen is used for mapping the Part and its Parameter for which the Gauge Repeatability and Reproducibility study shall be carried out. Gauge Repeatability & Reproducibility study can be carried out in three modes viz. Manual Entry, Single Instrument and Fixtures. Depending on the mode selected the way of capturing reading changes.

The user can add the part – parameter mapping by clicking on the Add button. The mapped record is only for the local machine. If a record has been mapped on one machine, then the readings for the record cannot be taken on another machine. For adding a record, the user has to first select a Reading Mode. After selection of the reading mode, the other details have to be selected.

Part Code – It is the Part for which the Gauge Repeatability & Reproducibility study has to be carried out. All the parts defined in the Part master are available in the Part Code drop down list box.

Instrument/Fixture Code – Instrument/Fixture code is the instrument that shall be used for taking the measurements. Depending upon the reading mode selected the Instruments or Fixtures are displayed. For further information on Instrument/Fixture Code

Parameter Code – Parameter code is the parameter for the selected Part, for which the Gauge Repeatability & Reproducibility study shall be carried out. For further information on Parameter

No. Of Operators – No of people who are involved in collecting the readings.

No of Trials – No of trials to be taken by each operator. For further information on No. Of Operators and No. Of Trials

Decimals – Precision for the readings to be taken and calculations

Reading Type – This is applicable only when the reading mode is set to ‘Fixtures’. This drop down list box displays five values viz. STATIC, MAX, MIN, TIR and AVG. Depending upon the Reading Type selected the measurement for the parameter shall be taken.

Master Value – Applicable when the reading mode is set to ‘Fixtures’. It is the master value for the Parameter.

Formulae – Applicable when the reading mode is set to ‘Fixtures’. It is the formula consisting of the probes that are used for the measurement.

Apart from the above you can get the information about the readings taken in the following format:

Parameter

Description

Last Trial Date

Last Trial Time

Trails Done

Type

Master Value

Formulae

Fixture Description

You may click on the Mastering button for mastering fixtures wherein you may calibrate the probes and specify gain factor. This is applicable if the Reading Mode of the Parameter is set to ‘Fixture’.

Click on the Readings button to take the readings for the Part and Parameter. On click of reading user screen will be launched for accepting operator details. Depending on the mode selected the way of capturing reading changes. See for further information Manual Entry  , Single Instrument , Fixtures

After the completion of all trials the parameter record is removed from the Part Parameter Mapping screen. This record shall now be available in the Calculations screen.

Modification and Deletion is allowed only if the trials have not begun for the Parameter that has to be modified or deleted.


Parameter (GRR)

The Part can be mapped to a specific Parameter for a local Machine only if, it has not been mapped to that Parameter earlier or if all the trials for that specific Part and Parameter are completed. If a Part has been mapped to a Parameter, with some Reading Mode for a machine, then the same Part cannot be mapped to the same Parameter with another Reading Mode for the same machine, until all the Trials for that Parameter have been completed. Maximum 16 Parameters can be mapped to a Part on a local Machine.

If the reading mode is Manual Entry or Single Instrument, then the Parameter Code drop down list box displays only the parameters that have been defined in the Part Parameter master and have not been mapped to the selected Part on the local machine.

If the reading mode is Fixture, then the Parameter Code drop down list box displays only parameters that have been defined for the selected Fixture in the Fixture Settings screen and have not been mapped to the selected Part on the local machine.


No. Of Operators and No. Of Trials (GRR)

For Fixtures reading mode once the No. Of Operators and No. Of Trials are specified at the first instance of mapping of a Part to any Parameter in the Fixture Reading Mode, the same value is applicable to all the other parameters being mapped to the same Part with Fixtures Reading Mode on the same local machine. You cannot specify different values of No. Of Operators and No. Of Trials later for the above mentioned.


Instrument/Fixture Code (GRR)

If the Reading Mode is selected as Manual Entry or Single Instrument, then the Instrument/Fixture Code drop down list box displays all the Instruments defined in the Instrument master.

If the Reading Mode selected is Fixtures, then the Instrument/Fixture Code drop down list box displays all the Fixtures defined in the Fixture master.


Calculations

The Calculation screen displays information of all the trials that have been completed. From this screen the Gauge Repeatability & Reproducibility report and Readings screen can be launched. Select a Part and its corresponding Parameter and click on the Report button to launch the Gauge Repeatability & Reproducibility Report. In this screen you need to choose Total Variation or Tolerance. Total Variation is calculated internally and displayed when you click on the Display Readings button. If Tolerance option is selected then you need to specify its value. Click on the Display Readings button to launch the Readings screen that displays all the readings of the Gauge Repeatability & Reproducibility study and its calculated values. No data on this screen can be added, modified or deleted.


Gauge Repeatability & Reproducibility Readings

This screen displays the readings that were taken for the Gauge Repeatability & Reproducibility studies. Measurement Unit Analysis, Equipment Variation, Appraiser Variation, Part Variation and Total Variation/Tolerance, Repeatability & Reproducibility values are displayed. Clicking on the XBarR Chart button can launch gauge Repeatability & Reproducibility X Bar R chart.

If one individual range per operator is greater than UCLr then you can discard that reading by clicking the Discard button. Clicking the Discard button causes those readings for which the individual range is greater than UCLr to be cleared from the grid and all the calculations are repeated. If more than one individual range per operator is greater than UCLr then the operator cannot discard those readings, in such a case clicking on the Discard button displays a message that – ‘Readings cannot be discarded, Repeat the readings.’

No data on this screen can be added, modified or deleted.


Gauge Repeatability & Reproducibility [Manual Entry] screen

 In this screen you can enter readings manually for part no’s randomly. Click on the Start button corresponding to the Part No for which the reading is to be entered. Enter the value in the textbox and click on the accompanying Stop button to save the value. Enter value for all the 10 parts and click Save & Close button to save the readings for the 10 parts and close the screen. Click on the Cancel button, if the user wants to discard the readings taken and close the screen. No data on this screen can be added, modified or deleted.


Gauge Repeatability & Reproducibility [Single Instrument] screen

In this screen you can take readings through the single instruments for part no’s randomly. Click on the Start button corresponding to the Part No for which the reading is to be entered and dump the value from the instrument. Take readings for all the 10 parts and click Save & Close button to save the readings for the 10 parts and close the screen. Click on the Cancel button, if the user wants to discard the readings taken and close the screen. You can modify the No. Of Channels, Serial Port and Parallel Port. No data on this screen can be added or deleted.


Fixture Mastering (Gauge Repeatability & Reproducibility) screen

This screen is used to set the calibration value and the gain factor. The calibration value is the deflection between the Master Value and the Current Reading. On the launch of the screen, the reading for all the parameters is displayed in the respective textboxes. You may set the calibration value by clicking on the Start button or using the hardware switch (i.e. foot switch or hand switch). After setting of the calibration value, the Gain Factor can be set using the up and down switch. You may set the Gain Factor and then store it using the Start button or the hardware switch. You may click the Start button again to launch the Measurement Screen for capturing the Gauge Repeatability & Reproducibility readings.


Fixture Measuring (Gauge Repeatability & Reproducibility) screen

This screen is used to capture the readings for the parameters. Readings can be taken for any part no randomly. You have to select the part no from the Part No drop down list box before capturing the readings. Click on the Start button or the hardware switch (i.e. foot switch or hand switch), readings for the parameters shall be displayed in the text boxes. Click on the Stop button to store the reading for the Part No. You may select part no’s from the drop down list box and continue the above-mentioned procedure to capture the readings. On completion of readings for the 10 part no’s, click the Save & Close button to save the readings. This one set of readings for 10 part no.’s is known as a trial. If the caption of the Start/Stop button is Start then you may click the Cancel button to discard the readings and close the screen. If the caption of the Start/Stop button is Stop then you may click the Cancel button to reset the readings from the probes in case of Dynamic parameters.


User (Gauge Repeatability & Reproducibility) screen

You have to enter the Code and Password. If the user Code and Password are valid then the Gauge Repeatability & Reproducibility Measurement Screen shall be launched based on the Reading Mode of the parameter that was selected. You are allowed to login, based on the No Of Trials specified per operator. If you have already completed the specified no of trials, then you will not be allowed to log in. Only the No Of Operators that was specified during Part Parameter Mapping shall be allowed to take readings.


Job Creation(old)

After creating a Work Order you may proceed to creation of a Job.  To create a new job record you may click on the Add button. You may create entirely new job or may create a rework order. This may be selected from the Type of Job group box.

Select the Work Order for which the Job is being created from the Work Order drop-down list. The Date and Part Number field is updated automatically. You may then assign a Batch Number from by selecting it from the drop-down list or entering the desired value. The Process assigned to a Part may be selected from the drop-down list or entered in the Process field. Similarly you may then select a Machine and assign it to the part for manufacturing from the Machine Number drop-down list. Click on Save to create Job.

If selected Part and Process are not mapped to fixture(s). Then created job will be available in Local Monitoring. If selected Part and Process are mapped to Fixture then created Job will be available for monitoring in Fixture Monitoring and Local Monitoring screens. If mapping is done with more than one fixture then all mapped fixtures are shown in Fixture Details grid and Measurement group box is enabled. You may select Measurement type and change the Sequence No. Of Fixture.

Measurement type can be

By Fixture

By Piece

This screen also allows you to create job for work orders selected for Internal Rework. For further information on Internal Rework


By Fixture

 Means you are allowed to take one set of reading form current fixture. Then automatically next fixture in sequence will be available for capturing readings.


By Piece

Means that you can take as many readings as you want on one fixture continuously. When you want to move to the next fixture in sequence for data capturing you have to select option for it on measurement screen.


Internal Rework

Click on Add button to create Rework Job. Then click on Internal Rework option in Type Of Job group box and select the Work Order for which the Job is being created from the Work Order drop-down list. The Date and Part Number field is updated automatically. You may then assign a Batch Number from by selecting it from the drop-down list or entering the desired value. The Process assigned to a Part may be selected from the drop-down list or entered in the Process field. Then you may select same Machine or new machine for creating Job for rework. Click on Save button to create Job.


Tool Type

Click on the Add button and add the tool Code along with its Description and also the Regrinding options and also specify the parameters. The No Of Reground value specifies the optimum no of times the tool can be reground. You have to select the parameters for the tool type. You may select the parameters from the parameter list for this tool type by checking in the boxes in front of their names. You can modify the Tool Type by clicking on the Modify button. You can modify the Description, No Of Reground and select new Parameters or deselect previously selected Parameters. You can modify the tool type only if tools have not been defined for the Tool Type in the Tools master or if the Tool Type is not linked to any Operation. You can delete the Tool Type by clicking on the Delete button. You can delete the tool type only if tools have not been defined for the tool type or if the tool type is not linked to any operation. Click on Save button to save the added/modified record.


Tool Master

The Tool Master displays the information of the tool and its parameters. Click on Add button to add a tool for a Tool Type. You can choose the Tool Type code from the drop-down list box. You have to enter the Code and Description for the tool. The Parameters of the selected Tool Type are listed in the table on the screen, but you cannot change the parameters. Click on Save button to save the tool.

You can modify the details of the Tool by clicking on the Modify button. If the status of the tool is reground, then you can regrind the tool by modifying the tool and checking the Reground checkbox. After regrinding the Sr. No. of the tool increments by one, Status of the tool becomes usable and this tool can be used for production. If the Status of the tool is Non-usable, then you can modify the tool and set the Status to usable, by checking the usable checkbox. After checking the usable checkbox, Sr. No. does not change. If the tool is being used in Production, then the Status of the tool is displayed as Issue. Tools with Status Usable are the tools that can be issued for production.

You can delete the tool, by clicking on the Delete button. You can delete a tool, only if it has never been used for production.


Model Shift Target

The Model Shift Target dialog box displays the Model Code and the Machine No. Based on the Model Code and Machine No information related to the Shift Code, Shift Description and Target Quantity are displayed. This screen is used to capture data for the target quantity that should be produced for a Model on a machine during a shift.

Click on the Add button to add a record. Select the Model from the Model Code drop down list box. Select the Machine No from the Machine No. drop down list box. All the Shifts defined in the Shifts master are displayed. You have to specify the Target Quantity for at least one shift. If some more shifts are added to the Shifts master after defining the Model Shift Target, then select the record from the Model Shift Target and modify it. Click on Modify button to modify the record. You can modify the target quantity and also specify the target quantities for the shifts that were defined later. You can delete the record by selecting the record and clicking on the Delete button. Click on Save button to save the added/modified record.


Machine Wise Operation

Machine Wise Operation dialog box gives the detailed information about the machine number and the operations that can be carried out on the machine. The link between the Machine and the Operation is defined here. All the operations that can be carried out a machine can be selected.

Click on Add button to add a link between the Machine and Operation. Select a Machine from the drop down list box. All the operations that are defined in the Process master are displayed in the list below the drop down list box. Select the operations by checking in the checkbox corresponding to the Operation that has to be linked to the Machine. At least one Operation has to be selected for a Machine. After selecting the Machine and its Operation, click on Save button to save the link.

You can change the selection of Operations for a Machine by modifying the record. Click on Modify button to modify the machine – operation link. Modification of a record is allowed only if model has not been defined for the selected Machine, in the Model Tool Link screen.

Click on Delete button to delete a link. You can delete the machine – operation link, only if model has not been defined for the selected Machine, in the Model Tool Link screen.


Operation Wise Machine

Operation Wise Machine dialog box gives the detailed information of the types of operations performed on the machines. The link between the Operation and the Machine is defined here. All the operations that can be carried out a machine can be selected.

Click on Add button to add a link between the Operation and Machine. Select an Operation from the drop down list box. All the machines that are defined in the Machine master are displayed in the list below the drop down list box. Select the machines by checking in the checkbox corresponding to the Machine that has to be linked to the Operation. At least one machine has to be selected for an operation. After selecting the Operation and its Machine, click on Save button to save the link.

You can change the selection of machines for an operation by modifying the operation – machine link. Click on Modify button to modify the operation – machine link. Modification of a record is allowed only if model has not been defined for the selected Operation, in the Model Tool Link screen.

Click on Delete button to delete a link. You can delete the operation – machine link, only if model has not been defined for the selected Operation, in the Model Tool Link screen.


Operation Tool Link

Operation Tool Link dialog box gives information about the Operation in association with the Tool Type and also its usage defined along with the Parameters and Unit Of Measurement. In this screen the link between the operation and tool types are defined. You can specify the usage of the tool, i.e. whether the tool type is specific to a model or if it is a common tool type. You can select the parameters of the tool type and also specify its unit of measurement.

To add a link for operation and tool type, click on the Add button. All the operations defined in the Process master are displayed in the Operation drop down list box. Select an Operation and then a tool type from the Tool Type drop down list box. By default the Tool Usage is common. If the Tool Type is specific to a model, then click on the Model Specific option button and also select its corresponding Model from the Model Code drop down list box. The Parameters of the Tool Type are displayed in the list provided in the screen. Checkboxes are provided for each parameter. For selecting a parameter, check the checkboxes corresponding the parameter. On checking a checkbox, a drop down list box is displayed under the column entitled Unit Of Measurement. The units of measurements defined in the Unit Of Measurement screen are available in the drop down list box. Select the appropriate unit of measurement for the parameters. Click on Save button, to save the added link.

Click on Modify button to modify the record. You can Modify the Tool Usage, select or deselect Parameters and change the Unit Of Measurement, only if Model has not been defined for the selected Operation and Tool Type, in the Model Tool Link screen.

Click on Delete button to delete the record. You can delete a record, only if Model has not been defined for the selected Operation and Tool Type, in the Model Tool Link screen.


Model Tool Link

Model Tool Link dialog box displays the information about the Model Code, Machine No., Operation and the Tool Type. The lower portion of the screen has two tab pages for Range and the Expected Tool Life. The model for a machine, operation and tool type can be defined in this screen.

To add a Model and Tool Link, the user can click on the Add button. Select the Model from the Model Code drop down list box. On selection of a model, its description is displayed in the adjoining text box. Similarly select the Machine No., Operation and Tool Type. All the machines defined in the Machine wise Operation screen or Operation wise Machine screen are displayed in the Machine No. drop down list box. If Machine and Operation link has not been defined then message will be displayed while adding the Model Tool Link. After selecting the Machine No., select the Operation. All the operations that have been defined for the selected Machine No. are displayed in the Operation drop down list box. Tool types defined for the selected Operation are displayed in the Tool Type drop down list box.

Range and Expected Tool Life tab pages display values for the selected Tool Type. Parameters defined for the selected Tool Type and Operation are displayed in the Range grid along with the Unit Of Measurement. The Range From and Range To fields determine the operating range value for the tool type parameters. Enter the From and To Range for all the parameters.

Expected Tool Life grid displays the Expected Tool Life and Alert Quantity for each Reground No. The Reground No. column displays value from 0 to the no. of optimum reground specified in the Tool Type screen. You have to enter the Expected Tool Life and Alert Quantity for each reground. The Expected Tool Life for a Reground No should be less than or equal to the Expected Tool Life of the previous reground. Alert Quantity for each reground should be less than or equal to its corresponding Expected Tool Life. Click on the Save button to save the record.

You can modify only the Range From, Range To, Expected Tool Life and Alert Quantity for a Model, Machine No., Operation and Tool Type. For modifying the record, you have to select Model, Machine No, Operation and Tool Type. If tools have been issued for the selected Model, Machine No, Operation and Tool Type, then while modifying the Range From and Range To values, if the values entered violate the operating value for the tool issued, then message is displayed stating that specified range is violating parameter values defined in Tool Issue.

You can delete a record, if tools have not been issued for the selected Model, Machine No, Operation and Tool Type. If tools have been issued then message is displayed stating that the record cannot be deleted since it is referenced in Tool Issue.


Tool Issue For Production

This screen displays the complete information about the tools issued for a model, machine and operation. Click on the Add button to issue tools. Select the Model, its corresponding Machine No., Operation and then the Tool Code for the tool to be issued. After selecting all the above-mentioned fields, the Parameters for the tool are displayed in the grid, along with the Unit Of Measurement, preferred operating Range of the tool parameter and the actual Value. While adding the tool i.e. issuing the tool enter data into the Value field. The Value for each parameter should lie within the Range specified for each parameter. This Value is the value at which the tool parameter shall be actually operated.

Select the record to be modified and click on Modify button. You can modify the parameter operating Value, only if production has not been started with the tool. If production has started then while trying to modify the record, message shall be displayed stating ‘Cannot Modify. Production done’.

For deleting a record, select the record and click on Delete button. You can delete the record, only if the tool has not started production for the selected Model, Machine and Operation. If the production has started then while trying to delete the record, message shall be displayed stating ‘Cannot Delete. Production done’.


Parameter Change

Once the production for a tool has been started for a Model, machine and Operation, the parameter operating values can be modified through the Parameter Change screen. All the tools that are currently being used for production are listed in this screen. You are not allowed to Add or Delete any record in this screen. For changing the parameter value, select the Model, Machine No., Operation and Tool code, and click the Modify button. The grid on the screen displays the Parameter, along with Unit Of Measurement, Range, Old Value and New Value. Enter the quantity produced by the tool till the time the parameter was changed, in the Shift Production Qty textbox. You can specify new parameter value for one or all the parameters for the tool. The Old Value column displays the current parameter value; the new value for the parameter has to be entered in the New Value column. If the New Value entered is not within the Range specified for the parameter, then message shall be displayed ‘New value is not within the range. Do you want to accept?’. You can save the New Value by clicking on the Save button. The Old Value for the parameter shall be updated with the New Value that was entered. If the New Value entered that within the Range of the parameter, then on saving the Old Value shall be updated without displaying any message.


Production

Production had done for a Model on a Machine No. for a particular Shift Date and Shift Code is specified in this screen. Click on the Add button to enter the production. Select the Shift Date, Shift Code, Model Code, Machine No., and Supervisor Code and enter the Shift Production. On click of the Add button, by default the current Shift Code is displayed. If model has been defined for the local machine, then that model and machine shall be displayed in the Model Code and Machine No. Drop down list box. You cannot enter production for shift dates greater than the current date. Click on Save button to save the record. After saving the record, if the quantity produced by the tool is nearing or has exceeded its Expected Tool Life then corresponding screens shall be launched, which shall display the expected quantity and the produced quantity.

You can modify the Shift Production only for the current Shift Date. Back dated production quantity cannot be modified.

You can delete the record only for the current shift date. Back dated record cannot be deleted. Click on the Delete button to delete the record.

Model Close facility is also provided from this screen. If the production for one model has been completed and you want to start with another model, then the previous model can be closed by clicking on the Model Close button. Select the model that is to be closed, and then click on the Model Close button, which shall launch a screen for selecting the new model. While closing model, the model shall be closed only for the machine that was selected for Model closure.


Tool Changing

If the life of a tool has been completed or for some reasons the tool has to be changed then the tool can be changed through this screen. For changing a tool, click the Add button. Select the Model, Machine No, Operation and Old Tool Code. By default the Model defined for the local machine shall be displayed in the Model Code drop down list box. Old Tool Code is the tool that has to be changed. On the selection of the Old Tool Code, the expected tool life for that tool is displayed in the Expected Tool Life textbox. Enter the production done for the shift till the time the tool was changed, in the Shift Production textbox. Select the Root Cause and Sub Cause for tool change. Remarks if any for tool change can be entered in the Remarks textbox. Select the Status of the Old Tool Code, i.e. whether the old tools should be reground, or if the tool is re-usable or non-usable. Select the new tool code, from the New Tool Code drop down list box, or if the tool to be selected is not present in the drop down list box, then you can directly type the tool code in the drop down list box. After selecting the new tool, you can save the record, by clicking on the Save button.

If the Status of Old Tool Code has been selected as Reground and the old tool code has already been reground for the optimum no of times as mentioned in the Tool Type screen, then a confirmation message shall be displayed stating that the tool has exceeded the optimum no of reground, do you want to continue with reground.

If the Status of the selected New Tool Code is Reground in the Tool Master screen, then Reground Serial No for the tool shall be incremented by one. If there are no records for the new reground no’s Expected Tool Life and Alert Quantity in the Model Tool Link screen, then you shall be prompted to enter the Expected Tool Life and Alert Quantity for the Reground Serial No. The entered Expected Tool Life should be less than or equal to that of the previous reground Serial No from Model Tool Link screen for that Model, Machine No, Operation, Tool Type Code. The Alert Quantity, should be less than or equal to its corresponding Expected Tool Life just entered for the New Tool Code, Reground Serial No.

You can modify only the last record that was added, by clicking the Modify button.  Shift Production, Root Cause, Sub Root Cause, Remarks, Status and New Tool Code can be modified. You cannot delete any record on this screen


Balance Tool Life

Balance Tool Life screen displays the information about the tools that are being used for Production for a Model Code and Machine No. By default this screen displays the Model Code and Machine No for the local machine, if no records exist for the local machine, then the first Model from the Model Code drop down list box shall be displayed. You cannot Add, Modify or Delete any record on this screen. The grid on this screen displays data for the Model Code and Machine No selected in the drop down list box. The grid displays the Operation, Tool Code, Tool Description, Reground, Expected Tool Life, Produced Previous, Produced Current and Balance.

Reground – It is the current reground serial no for the Tool Code

Expected Tool Life – It is the Expected Tool Life for the Tool Code for a Model, Machine, Operation and Reground Serial

Produced Previous – It is the quantity produced by the Tool Code if that tool was previously used for Production of some Model

Produced Current – It is the quantity produced by the Tool Code for the selected Model and Machine

Balance – It is the quantity that can be produced by the Tool Code so that it reaches its Expected Tool Life.


Tool Life Nearing screen

This screen is displayed after entering the Production in the Production screen, if the tools are nearing their expected tool life. If the quantity produced by a tool has exceeded or is equal to its Alert Quantity but is less than its Expected Tool Life, then this screen is displayed. The screen displays a list of all the tools that are nearing their expected tool life.

Tool Code and Tool Description display the Tool code and its description for the tools that are nearing their expected tool life.

Expected Qty and Alert Qty columns display the Expected Tool Life and Alert quantity as entered for the Tool Type and its particular Reground Serial No. in the Model Tool Link screen.

Current Balance Life is the amount, which can be produced by the Tool, so that its total production is equal to its expected tool life. Current Balance Life is calculated on the basis of the percentage balance life of the Tool. Percentage Balance life is the quantity which can be produced by the tool after some production has been done. For e.g. if expected tool life of a tool is 1000 and 250 has been produced by the Tool, then its Percentage Balance Life is 75%, which means that 75% of its expected tool life can be produced by the Tool.

Percentage balance life = (100 – ((100 * Total Production) / Expected Tool Life from Model Tool Link)

Current Balance Life = (Expected Qty from Model Tool Link * Percentage Balance Life)/100

If a tool has been used in more than one model, then the Current Balance Life denotes the quantity that can be produced by that tool for the selected Model and Machine, based on its Expected tool life and Percentage Balance Life.

Current Alert Quantity is the amount, which can be produced, so that the total production is equal to the alert quantity.

Current Alert Qty = (Alert Qty from Model Tool Link –

  	       (Expected Qty from Model Tool Link * (100 - Percentage Balance Life) / 100)

Produced Qty is the total amount that has been produced by the Tool Code for the Model and Machine.


Tool Life Exceeded Screen

This screen is displayed if the production entered in the Production screen causes the tool to exceed its expected tool life. The screen displays a list of all the tools that have exceeded their Expected Tool Life. A textbox is provided for Remarks to be entered by the supervisor.

Tool Code and Tool Description display the Tool code and its description for the tools that are nearing their expected tool life.

Expected Qty column displays the Expected Tool Life as entered for the Tool Type and its particular Reground Serial No. in the Model Tool Link screen.

Current Balance Life is the amount, which can be produced by the Tool, so that its total production is equal to its expected tool life. Current Balance Life is calculated on the basis of the percentage balance life of the Tool. Percentage Balance Life is the quantity that can be produced by the tool after some production has been done. For e.g. if expected tool life of a tool is 1000 and 250 has been produced by the Tool, then its Percentage Balance Life is 75%, which means that 75% of its expected tool life can be produced by the Tool.

Percentage balance life = (100 – ((100 * Total Production) / Expected Tool Life from Model Tool Link))

Current Balance Life = (Expected Qty from Model Tool Link * Percentage Balance Life)/100

If a tool has been used in more than one model, then the Current Balance Life denotes the quantity that can be produced by that tool for the selected Model and Machine, based on its Expected Tool Life and Percentage Balance Life.

Produced Qty is the total amount that has been produced by the Tool Code for the Model and Machine.


Supervisor Login screen

This screen is displayed if the production entered in the Production screen causes the tool to exceed its expected tool life. Login screen is displayed, and only the supervisor is allowed to log into the screen. If the Code and Password entered are of a valid supervisor then the Tool Life Screen (exceeded) is displayed. All the users defined in the Supervisor master screen are referred as Supervisors.


Tool Change Corrective Action screen

While taking readings through fixtures, trends may be raised. If a trend is raised then the user has to take a corrective action based on the settings done in the Trend Settings screen. In the Corrective Action for Trends screen, if you select the Root Cause as TC – Tool Change, then after the close of the Corrective Action For Trends screen, the Tool Change screen is launched. You can change the tool(s) from this screen by clicking the Add button. Data for Model Code, Machine No. and Operation is retrieved from the Job for which the measurements are being taken. Select the Old Tool Code, enter the quantity produced by the Old Tool Code during the current shift in the Shift Production text box, select the Status for the Old Tool Code and select the new tool code from the New Tool Code drop down list box. If the required New Tool Code is not present in the drop down list box, then you can directly type the code and description for the New Tool Code in the drop down list box and the adjoining textbox respectively. You can save the record by clicking the Save button, or click the Cancel button to cancel the adding of the record. You can close the screen by clicking on the Close button.

If the status of the Old Tool Code has been selected as Reground and the Old Tool Code has already been reground for the optimum no of times as mentioned in the Tool Type screen, then a confirmation message shall be displayed stating that the tool has exceeded the optimum no of reground, do you want to continue with reground.

If the status of the selected New Tool Code is Reground in the Tool Master screen, the Reground Serial No for the tool shall be incremented by one. If there are no records for the new reground no’s expected tool life and alert quantity in the Model Tool Link screen, then you shall be prompted to enter the expected tool life and alert quantity for the reground serial no. The entered expected tool life should be less than or equal to previous reground Serial No from Model Tool Link screen for that Model, Machine No, Operation, Tool Type Code. The alert quantity, should be less than or equal to its corresponding expected tool life just entered for the new tool code, reground serial no. Modify and Delete functionality is not applicable in this form.


Tool Parameter Change corrective action screen

While taking readings through fixtures, trends may be raised. If a trend is raised then the user has to take a corrective action based on the settings done in the Trend Settings screen. In the Corrective Action for Trends screen, if the user selects the Root Cause as TPC – Tool Parameter Change, then after the close of the Corrective Action For Trends screen, the Tool Parameter Change screen is launched. You can change the operating parameter values through this screen. Data for Model Code, Machine No and Operation is retrieved from the Job for which the measurements are being taken. Select the Tool Code for which the operating parameter values are to be changed and then clicking on the Modify button. The grid on the screen displays the Parameter, along with Unit of Measurement, Range, Old Value and New Value. Enter the quantity produced by the tool during the current shift, in the Shift Production Qty textbox. Enter the new parameter value for one or all the parameters for the tool. The Old Value column displays the current parameter value; the new value for the parameter has to be entered in the New Value column. If the New Value entered is not within the range specified for the parameter, then message shall be displayed stating ‘New value is not within the range. Do you want to accept?’. Save the New Value by clicking on the Save button. The Old Value for the parameter shall be updated with the New Value that was entered. If the New Value entered that is within the range of the parameter, then on saving the Old Value shall be updated without displaying any message.


Model Close screen

Model Close screen is launched from the Production screen on the click of Model Close button. Model Close screen consists of a New Model Code combo, a list view and a grid. New Model Code combo is populated with all the Models defined in Model Tool Link except the Model, which is selected for closing. The List view displays the Tool Code, Description, Status and Operation. For more information on Status

The grid displays the Operation, Parameter, Unit Of Measurement, Range and Value. Select the new model from the New Model Code combo. On selection of the Model from the combo, the textbox corresponding to the Model Code combo displays the description of the selected Model, the list view is populated with all the tool codes, which are applicable to the selected Model and the Machine for which the Model was closed. If the selected Model is a model, which was closed earlier, then all the tools that were used by the Model when it was closed shall be displayed along with all the other tools that are applicable to the Model and Machine.

Every item in the list view also displays the Operation linked to the tool. The list view consists of checkboxes for each list view item. Select the Tools from the List view to issue the tools for the new model. You can check or select only the tools that have their status as Used or Available. You cannot select tools with status as Reground or Non Usable. These tools are displayed only for displaying the information about the tools that were used. If you try to select such a tool then message is displayed stating that the tool cannot be used.

On selection of a tool from the list view, the grid below the list view displays all the parameters applicable to the tool, along with the operation of the tool and unit of measurement for the Parameter, Range of the Parameter and the value for the Parameter.

If a tool is listed more than once in the list view for different Operations, then you can select only one tool from it. If you try to select the same tool more than once then a message shall be displayed stating that the tool has already been selected. You have to select at least one tool for the new model. After selecting the Tools to be issued for the New Model Code, click of OK button, to issue the selected tools for the New Model Code.


Status of tools in Model Close screen

If the tools that were used by the Model earlier are not issued to some other model and are in the Usable state in the Tool master, then its Status is displayed as Used in the list view.

If the tools that were used by the Model earlier are not issued to some other model and are in the Reground state in the Tool Master, then its Status is displayed as Reground in the list view.

If the tools that were used by the Model earlier are not issued to some other model and are in the Non-Usable state in the Tool Master, then its Status is displayed as Non Usable in the list view.

All tools other than the tools that were used by the Model earlier are displayed in the list view with their status as Available.

If the Status of the Tool is Used, Reground or Non Usable, then on selection of the Tool from the list view, the grid displays the values for the parameters on which the tool had operated for the Model. You can modify the value of the parameter(s), by checking the check box corresponding to the tool and then entering value in the grid for the parameter(s).

If the status of the tool is available then the Value column of the grid is empty. If you select a tool with Status as Available, then you have to enter the value for all the parameters for that tool.


Charts

You may view the Charts for a Job when Local Monitor, Fixture Monitor or Global Monitor screen is active. Select the Job from one of the above-mentioned screen and click on Charts from Report option of Main menu. You will get the Date and time dialog box. Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of charts. You can view all the charts, which are selected in Work Order QAP.

Normality Test -

Click on the Chart → Option → Normality Test

If Perform Normality Test is checked in the chart options screen then either Anderson-Darling or Chi-Square Test will be carried out depending on the selection.

If it is unchecked then the Anderson-Darling or the Chi-Square test is not carried out and the results are displayed on charts according to the standard normal method

In this case the Chi-Square, Conf.Level, Degree of Freedom, Result will display ‘NA’ as value on the chart screen. The note will display ‘Using Standard Normal method’. The Cp, Cpk and Pp, PPk will display the values calculated using the standard normal method.

   For Chi-Square test to be carried out the following condition should be satisfied - The Number of reading for Cpk

   (Minimum readings for normality test) from Job parameter is greater than or equal to the actual readings taken.

If data is normal then result displayed is "Data is normal" and Cp, Cpk, Pp, Ppk will be displayed and calculated using Standard Normal Method. If data is not normal then for Chi-Square, Deg. of freedom and Conf. Level will be displayed and for Anderson-Darling the Deg.of freedom and Conf level will not be displayed instead AD Value and Critical Value will be displayed on the screen.

Result displayed is "Data is not normal" and based on transformation method selected i.e. non-parametric, Box-Cox, Cp, Cpk, Pp, Ppk will be displayed. If Box-Cox transformation is selected then Cp, Cpk, Pp, Ppk will be displayed and calculated using Box-Cox method and Note displayed is "Using Box-Cox Transformation Method". If Non-parametric method is selected   then for Cp and Cpk it will display "NA" and Pp and Ppk will be calculated using non-parametric method and Note displayed "Using Non-Parametric Method".  In Box-Cox transformation, if excel is not installed then result displayed is "Excel application is not installed", chi-square, Conf. Level, Deg. Of freedom is displayed and Cp, Cpk, Pp, Ppk will be displayed with "NA" and note will not be displayed. If data is –ve then result displayed is "Data is negative" chi-square, Conf. Level, Deg. Of freedom is displayed and Cp, Cpk, Pp, Ppk will be displayed with "NA" and note will not be displayed.

If data is insufficient then result will display Result  "Insufficient Data" or Data is not proper for Chi-Square Test then result will display "Data is not proper for Chi-Square Test" then Chi-square, Deg. Of freedom, Conf. Level, Cp, Cpk, Pp, Ppk will display "NA". Note will not be displayed

For variable parameter the charts available are Histogram, X Bar R, X Bar S, X-MR, X, Pre-control & Pareto charts.

For attributive parameter the charts available are P, nP, C & U charts.

For all Line Charts: To view details of all actual readings for the samples, use the mouse to move the cursor to the points plotted on the chart.

Click on Cancel to leave this dialog without making any modifications or to cancel the operation.

Chart Mailing Facility -

The Chart Mailing facility is provided in the frmChart Screen.

The File menu of the CHART screen will be having one menu option as EMAIL with two sub-menus viz. Send As Image and Send As PDF.

Click File>Email>Send As Image option then the Chart will be zoomed to 200% and the Zip file of the Image file will be attached to the Mail. The Zoomed Chart will be displayed on the screen along with the compose window.

Click File>Email>Send As PDF>Generate PDF option. The user is given a message "Please enter the File Name in C:\DSS" then the PDF will be generated at the given path in PRIMO PDF window. (Folder will be created, if the folder doesn’t exits) The user must enter the file name in the "save as" textbox "C:\DSS\".

Chart form will have menu with following menu options.

File  - file menu with sub options Save as Image & Save as Image for QS9000, Email, Close current chart and Exit option for closing chart form and return back to measurement screen or to monitoring screen.

Save as Image for QS9000 menu option will get enabled only when Histogram is active.

Save as Image will be enabled for any chart is active under File menu.

When click on Save as Image or Save as Image for QS-9000 it will open Save As Dialog box with File name as paracode-Type of chart – DD-MMM-YYYY-HHMMSS and the active path is the last path which you had saved. Click on Save it will get store in the App path [if the last path selected as App Path] or other directory if you choose differently from Save in Combo. Click on Cancel it will not get stored.

Delete Reading/Sample –

•	Single Instruments Multiple Parameter-

When sample is not completed, User right click on Reading & click on Delete Reading/Sample then system will prompt the message "Are you sure you want to delete this reading" & if user press Yes then

Reading for all parameter related to selected job is deleted & Chart get refresh with updated Reading Serial No with Reading

If user clicks on No then reading for all parameter is not deleted.

When sample is completed & User right click on Reading & click on Delete Reading/Sample then system will prompt the message "Are you sure you want to delete this sample" & if user press Yes then

•	It will check for corrective action, if corrective action has been taken or not, if corrective action has been taken then it will display. "Corrective action has been taken. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on yes the sample for all parameter related to selected job is deleted & Chart get refresh.

•	It will check for corrective action, if records exist in the same. If records exist, then it will display. "Trends have been raised. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on yes then sample for all parameter related to selected job get deleted & & Chart get refresh.

If user press No then No sample for all parameter get deleted.

•	Multiple Instruments -

When sample is not completed, User right click on Reading & click on Delete Reading then system will prompt the message "Are you sure you want to delete this reading" & if user press Yes then

Reading for that parameter related to selected job is deleted & Chart get refresh with updated Reading SerialNo with Reading

When sample is completed & User right click on Reading & click on Delete Reading then system will prompt the message "Are you sure you want to delete this sample" & if user press Yes then

•	It will check for corrective action to see if corrective action has been taken or not, if corrective action has been taken then it will display. "Corrective action has been taken. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on yes the sample for that parameter related to selected job is deleted & Chart get refresh

It will check for corrective action to see if records exist in the corrective action. If records exist in the corrective action then it will display. "Trends have been raised. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on yes then sample for that parameter related to selected job get deleted & Chart get refresh

Event Remark Facility

In Chart offline/online when the user right clicks on the reading no, it displays three menu options only when Chart is X Bar R, X , X-MR otherwise two menu option add remark, view remark and Delete Reading/Sample. When the user clicks on add remarks, remarks for reading screen are displayed. User is allowed to enter the remarks and click on Ok, which will launch reading sample screen. If the user clicks on cancel it will still launch reading sample screen. If a remark is present then it will show the remarks for the selected reading else it will show the Reading Sample screen


History Charts

You may select the part from the Part No drop-down list. You may select the Process from the Process drop-down list. You may select the Work Order No, Date, Machine No, Job Start Date-Time from respective drop-down list. You may check the Filter check box, of Job Start Date to display only the Jobs created between the specified dates. When this check box is checked, two drop-down lists will appear on the dialog box. They may be used to set the From and To dates. Depending upon From and To dates Machine Number & Job Start Date-Time drop down list is populated. History Charts can be launched only for closed jobs, if the readings have been taken.

Click on the OK button to confirm the selection and proceed with the generation of reports. You can view all the charts i.e. depending upon the type of parameter, which were selected at the time of creation of work order for a selected job.

For all Line Charts: To view details of all actual readings for the samples, use the mouse to move the cursor to the points plotted on the chart.

Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


History Summary Report

You may select the part from the Part No drop-down list. You may select the Process from the Process drop-down list. You may select the Work Order No, Date, Machine No, and Job Start Date-Time from respective drop-down list. You may check the Filter check box, of Job Start Date to display only the Jobs created between the specified dates. When this check box is checked, two drop-down lists will appear on the dialog box. They may be used to set the From and To dates. Depending upon From and To dates Machine Number & Job Start Date-Time drop down list is populated. History Summary Report can be launched only for closed jobs, if the readings have been taken.

Click on the OK button to confirm the selection and proceed with the generation of reports. History Summary Report gives the idea about the summary of a selected closed job. It shows the total number of readings, control limits, Mean, S.D., Pp, Ppk, Cp & Cpk for all parameter for selected closed jobs. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


History Readings Report

You may select the part from the Part No drop-down list. You may select the Process from the Process drop-down list. You may select the Work Order No, Date, Machine No, Job Start Date-Time from respective drop-down list. You may check the Filter check box, of Job Start Date to display only the Jobs created between the specified dates. When this check box is checked, two drop-down lists will appear on the dialog box. They may be used to set the From and To dates. Depending upon From and To dates Machine Number & Job Start Date-Time drop down list is populated. History Charts can be seen only for closed jobs if the readings have been taken.

Click on the OK button to confirm the selection and proceed with the generation of reports. History Readings Report gives the idea about all details related to closed jobs.  It shows the readings of all parameters, average and range for a sample. It shows the Max value, Min value, control limit, Cp, Cpk, Accept and Reject, S.D. for a selected job. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Work Order Analysis

You may select the customer by selecting the customer code from the Customer Code drop down list. This will display a list of work orders available to be included in the report in the Work Orders Available list.   You may then use selection/de-selection buttons on the forms to move the appropriate work-orders in the Work Orders Selected list. Work order analysis Report can be launched only for closing the jobs that have been closed.

Click on the OK button to confirm the selection and proceed with the generation of reports. Work Order Analysis Report gives the idea about all the work orders for a selected customer. It shows the Mean, S.D.,

LCL, UCL, Pp, Ppk, Cp, Cpk for each parameter of the selected work order. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Gauge Calibration Due

Select the dates to mark the period from Period from and To drop-down lists. The instruments available for calibration are displayed in the Instruments Available list. You may then use the selection/de-selection buttons to move the instruments to The Instruments Selected list. Gauge Calibration Due Report is used to display the instruments that have to be calibrated during the specified period.

Click on the OK button to confirm the selection and proceed with the generation of reports. It displays the information about instrument along with the calibration date, location & who is responsible for the same. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Gauge Calibration Overdue

Select the Gauge Calibration Overdue As On date. You then get a list of Available Instruments No, for which the report may be generated. You may then use the selection/de-selection buttons to move the instruments to the Selected Instruments No list. Gauge Calibration Overdue Report is used to display the instruments that are overdue for calibration on the specified date.

Click on the OK button to confirm the selection and proceed with the generation of reports. It displays the information about the instrument along with the calibration due date, location & who is responsible for the same. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Machine wise analysis

You may first select the machine from the Machine No drop-down list. You may then select the dates to mark the period from the Period From and To drop-down list. Machine-wise Analysis Report can be launched only for jobs that have been closed.

Click on the OK button to confirm the selection and proceed with the generation of reports. Machine-wise Analysis report gives the idea about part, process and all work orders, control limits, Cp, Cpk, Pp & Ppk. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Quality Assurance Plan Summary

You may generate a report on the summarized Quality Assurance Plan by selecting the option Quality Assurance Plan Summary from the Main menu. Quality Assurance Plan Summary report gives the idea about all related to Part, Process & Parameters. For each parameter which instrument has been used for dumping the reading, what are the Specification limits, control limits, unit of measurement, Sample size & frequency.

Note:  When the report is generated two buttons are added to the toolbar menu. Also a list box is displayed for setting the zoom level for easy viewing of the report on the screen. When the report is generated you may print it by clicking the Print button on the toolbar menu. You export report in HTML or Text format by clicking the Export button on the toolbar menu.  You set the zoom level to desire by selecting a suitable value from the Zoom drop down list.


Quality Assurance Plan Detail

 Select a part(s) from the Parts Available list, you may then use the selection/de-selection buttons to move the selected part(s) to the Selected Parts list. Quality Assurance Plan Detail gives the details related to a Part.

Click on the OK button to confirm the selection and proceed with the generation of reports. Quality Assurance Plan Detail gives the detailed information about quality assurance plan for the selected part(s). Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Pending Non Conformities

You may then specify the period to look for the pending non-conformities by setting the dates in the fields Period from and Period to.

Pending Non Conformities Report can be seen only when the corrective action has not been taken for a sample within a job.

Click on the OK button to confirm the selection and proceed with the generation of reports. Pending Non Conformities Report gives the information about the jobs for which the corrective action has not been taken for a sample. It displays the details about the sample like Sample Date, Sample Time, Work Order Number, Work Order Date, Part No, Process, Parameter and Machine Number. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Overdue Non Conformities

You may then specify the date in the field As On Date.

Overdue Non Conformities Report can be seen only when the corrective action has been taken but not completed.

Click on the OK button to confirm the selection and proceed with the generation of reports. Overdue Non Conformities Report gives the information about the samples of the job for which the corrective action has been taken but not completed. Details mentioned in the Corrective Action screen can be viewed in this report. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Disposal Action (Date Wise)

You may generate a report on the disposal actions taken during specified dates through this screen. You may then specify the period by setting Period from and Period to fields. The list of the parts disposed in the period is displayed in the list Available Part Numbers and Selected Part Numbers. You may then select the parts to be included in the reports using the selection/de-selection buttons.

If you had taken any disposal action during collection of data or offline then only this reports can be launched.

Click on the OK button to confirm the selection and proceed with the generation of reports. Disposal Action Date wise report displays the disposal actions that have been taken for the nonconformities. This report gives the information Date wise. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Disposal Action (Part Wise)

You may generate a report on the disposal actions taken for the selected parts through this screen. You may then specify the period by setting Period from and Period to fields. The list of the parts disposed in the period is displayed in the list Available Part Numbers and Selected Part Numbers. You may then select the parts to be included in the reports using the selection/de-selection buttons.

If you had taken any disposal action during collection of data or offline then only this report can be launched.

Click on the OK button to confirm the selection and proceed with the generation of reports. Disposal Action Part wise report displays the disposal actions that have been taken for the nonconformities. This report gives the information about Part wise. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Audit Trail For Homogenized Samples

Click on the OK button to confirm the selection and proceed with the generation of reports. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.

You may generate the Audit Trail For Homogenized Samples report through this screen. On the screen you have to specify the following ranges by selecting appropriate values for the fields listed below:

Part No - select From Part No and To Part No list boxes

Process - select From Process and To Process list boxes

Parameter - select From Parameter and To Parameter list boxes

Deleted date - select From Deleted Date and To Deleted Date list boxes

Drop down lists of all controls will be filled up only when samples have been homogenized from charts.

Click on the OK button to confirm the selection and proceed with the generation of reports. This report displays the details about when the sample has been homogenized and remarks that have been entered while homogenizing. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Cost of Internal rejection

Use this option to generate a report on the parts rejected during internal quality testing. Specify the required period by entering Period From and Period To. Select the required parts from the Available Parts list using the selection/de-selection buttons.

This report can be seen only after closing the Job and if the Disposal Action has been taken.

Click OK to confirm the selection and proceed with the generation of report. This report provides details about the Cost of raw material, Cost of repair, Cost of processing and the Disposal action for a closed job. Click Cancel to exit.


Summary Report

You may generate a report on Summary Report when Local Monitoring or Fixture Monitoring or Global Monitoring screen is active. Select the Job from one of the above-mentioned screen and click on Summary report from Report of Main menu.  You will get the Date and Time dialog box.  Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of reports. Summary Report provides summary of the selected job during the specified period. It displays the control limits, Mean, S.D., Pp, Ppk, Cp & Cpk for all parameter for selected job. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


All Parameter Readings Report

You may generate a report on All Parameter Readings Report when Local Monitoring or Fixture Monitoring or Global Monitoring screen is active. First Select the job from one of the above-mentioned screen and click on All Parameter Readings Report from Report of Main menu.  You will get the Date and time dialog box.  Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of reports. All Parameter Readings Report provides all details related to that job. It shows the readings of all parameters for selected job. It displays the average and range for a sample. It shows the Max value, Min value, Control limit, Cp, Cpk, Accept and Reject, S.D. for a specified period for a selected job. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Corrective Action Trend Report

You may generate a report on Corrective Action Trend Report when Fixture Monitoring or Global Monitoring screen is active. Select the job from one of the above-mentioned screen and click on Corrective Action Trend Report from Report of Main menu. You will get the Date and time dialog box.  Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of reports. Corrective Action Trend report displays the information about when and which trend was raised for the selected job during the specified period, and the corrective action that was taken for the trend. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Fixture Mastering Report

You may generate a report on Fixture Mastering Report when Fixture Monitoring or Global Monitoring screen is active. Select the job from one of the above-mentioned screen and click on Fixture Mastering Report from Report of Main menu. You will get the Date and time dialog box.  Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of reports. Fixture Mastering report gives the details about when the calibration or mastering has been done for a fixture for a selected job. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Balance Tool Life

All running Models or closed Models are displayed in the Models Available list. You may use selection and de-selection buttons to move these available Models to include in the report.  In this report you can see the balance life of the tool.

Click on the OK button to confirm the selection and proceed with the generation of reports. Balance Tool Life Report displays the balance life of a tool that has been used or is in use by a Model. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Model Wise Report

All running Models or closed Models are displayed in the Models Available list. You may use selection and de-selection buttons to move these available Models to include in the report.

Click on the OK button to confirm the selection and proceed with the generation of reports. Model Wise Report displays the detailed information about the tools, its parameters, operating values and life of the tool for the selected Model(s). The information in this report is displayed Model wise. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Operation Wise Report

All machines, which are manufacturing Models, are displayed in the Machine Available list. You may use selection and de-selection buttons to move these available Machines to include in the report.

Click on the OK button to confirm the selection and proceed with the generation of reports. Operation Wise Report displays the detailed information about the tools and life of the tool for the selected Machine(s).  The information in this report is displayed Operation wise. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Production Report

You may then specify the period by setting Period from and Period to fields.  The Machine Numbers are populated in the drop down list for which the production has been done.

Click on the OK button to confirm the selection and proceed with the generation of reports. Production report gives the details about production of a model for a machine and shift for a specified period. The target shift quantity that is mentioned in the Model Shift Target screen is displayed. This assists you in knowing the actual produced quantity and the desired target quantity. Supervisor of each shift is also displayed in the report. Supervisor name is displayed in the color that is specified in the Supervisor master. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Tool Parameter Change Report

You may then specify the period by setting Period from and Period to fields.  The Tool Codes are populated in the drop down list for which the parameter value has been changed.

Click on the OK button to confirm the selection and proceed with the generation of reports. Tool Parameter Change report gives the idea about the life of a tool for different values of the parameter. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Tool Change Report

You may then specify the period by setting From and To fields.  If the tool has been changed within the specified date i.e. From and To fields, then the reports can be launched.

Click on the OK button to confirm the selection and proceed with the generation of reports. Tool change report will gives the idea about when the tool was changed and the reason for the same. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


Data Acquisition In ProQMS

The acquisition of the process data may be done using the following input devices:

Keyboard

Electronic probes

Digital instruments

RS 232/RS 485

The software acquires quality parameter data and checks if it is in the specified limits of tolerance. The process behavior may be observed with respect to the limits of tolerance.

Pro QMS uses common yet elaborate statistical techniques that help in analyzing the process data and alarm if the process is deviating from the "normal" behavior. It is expected from the user to take the decisions when the deviation is detected.


Collecting the data for variable type parameters (Measure screen)

If the parameter has been defined as variable then you may collect actual measured data. Click Measure button of Local Monitoring screen. Then ‘Measure For Variable Type’ screen will be launched for entering readings for variable parameters. The Measure form displays the details of the Job such as Work Order, Part, Process, Parameter, Instrument used, Unit of Measurement, Channel No, and Sample Size along with the details of the Parameter.

Based on the Sampling Technique used, the formula for the calculation of the control limits and Standard Deviation changes. For further information on Sampling technique. If Sampling Technique is Sampling then the mean of the readings just taken is displayed in the Mean textbox. Mean and the readings textbox is disabled, focus is set on the close button.  If Sampling Technique is 100 % Inspection then the mean of sample (pseudo sample) will be calculated and displayed but reading text box will remain enabled. The trend is displayed using an icon, depending on the value of the mean.  Clicking on the close button closes the form

You can take readings for the selected job, by entering value in the Readings textbox. The readings are taken depending upon the Sample size. As the reading is taken, the reading is displayed along with a color in the flex grid. See Coloring of Reading for further information. Reading displayed on grid is setting value plus actual observation (reading) entered in reading text box.

If the reading entered is out of the Control Limits, a message is displayed to the user for conformation of accepting the reading. If user selects yes, the reading is accepted and is displayed in the grid along with the corresponding color. If user selects no, the entered value is discarded and the focus is set on the reading textbox.

The online chart displays the no of points depending upon the value entered for the display of Online Points in the Company Settings form

On this screen readings can be captured in two modes, viz. Manual and Automatic. For further information on Reading Modes.

Reading types available are Continuous or Interactive. For further information on Reading Types

   Measurement


Reading Types

If the Reading Mode is Automatic and Reading Type is Interactive, then for every reading the message "Press OK to take measurement" will be displayed. You have to click on OK button of message and then release data from connected instrument. Data received from instrument will be displayed in reading text box

If Reading Mode is Automatic and Reading Type is Continuous, then the message "Press OK to take measurement" will be displayed only for first reading.


Reading Modes of Measure Screen

Reading Mode for capturing data can be Manual or Automatic.

In case of Manual Mode – Data entered in reading text box is saved into database. Reading entered in text box is dumped into database on pressing the Enter Key.

In case of Automatic Mode – Data is captured based on instrument and interface selected. Various interfaces, which are allowed through PROQMS, are

PMDI – 8 Channel Interface

PMDI – 16 Channel Interface

WB – Weighing Balance

BK941 – Baker 941 unit

BKCALP – Baker Caliper

In case of Automatic Mode, if the instruments selected are due for calibration then the message "Instrument(s) due for calibration Instrument Number" is displayed.


Sampling Technique

If Sampling Technique of selected job is Sampling then it displays following information for the parameter – LSL, USL , LCLx, UCLx, UCLr, LCLr, Pp, Ppk, Cp, Cpk, and Setting Value. UCLx and LCLx are control limits of X Bar R Chart, Standard deviation used in calculating Cp based on R bar i.e. average of subgroup range. The form also displays an online chart X Bar R chart for the selected Job. The chart is updated on completion of one sample.

If Sampling Technique of selected job is 100% Inspection then following information for the parameter will be displayed – LSL, USL, LCLx, UCLx, UCLmr, LCLmr, Pp, Ppk, Cp, Cpk, and Setting Value. UCLx and LCLx are control limits of X – MR Chart. Standard deviation used in calculating Cp based on R bar i.e. average of Moving range. X – MR chart will be displayed as online chart. The chart is updated after every reading. Pseudo Sample entered in Work Order QAP is used for calculating statistical constants (D3, D4, E2, D2)

Field ‘Display Cpk or Ppk value.’ added to know the system to calculate Cpk or Ppk based on the last sample numbers, if user enter 0 (zero) then system will calculate the Cpk or Ppk based on all sample. If user put the sample no 20 then system will calculate for last 20 samples.


Coloring of Readings

The color displayed along with the reading depends on whether the reading value is within Control Limits, out of Control Limits or Out of Specification Limits.

Within Control Limits – Green color

Out Of Control Limits but within the Specification limits – Yellow color

Out Of Specification Limits – Red color.


Collecting the data for attribute type parameters

If the Parameter Type has been defined as Attribute then you may collect the data in the

Form of No. Of Defectives or No. Of Defects.

This screen displays Part, Process, Parameter, Work Order, Batch and Subgroup Size for selected Job and Parameter. If Subgroup Size entered in Work Order QAP for that particular parameter is greater than 0 then Subgroup Size field will be disabled. Otherwise Subgroup Size will be enabled and you may enter the value for Subgroup Size.

If the charts selected for the particular Parameter are nP or P or both (P and nP) then the label will be No. Of Defectives. If chart selected are C or U or both (C and U) then the label will be No. Of Defects. On the click of OK button readings will be saved to database.


Collecting Data For Pre-Control Chart

If in Work Order QAP for parameter, Pre-Control Chart is selected, then this screen for accepting reading will be launched on click on Measure button of Local Monitoring screen. The screen displays details of selected job and pre control chart.

Readings can be entered in reading text box. If you enter 5 reading it will be plotted and validated as follows.

Algorithm followed for validation of setting

Approve setting when 5 consecutive readings are in GREEN zone.

If one is in YELLOW zone, check another 5 readings.

Follow step 1 and approve or adjust if one reading is in YELLOW zone.

If 2 readings are in YELLOW zone Adjust and Repeat step 1.

If one is in RED zone display message stop and repeat step 1.

A thick vertical line separates the Setting region from Run region. Setting region accommodates first 5 readings, which are used for a successful setting. Once setting is approved then readings can be taken for validating runs.

Algorithm followed for validation of Run

At a time only one reading will be entered and this reading will be compared with the previous reading to check for the run.

Displays the messages ADJUST THE PROCESS if the current entered reading and previous reading are in YELLOW Zone.

Display the message STOP THE PROCESS if the current entered reading is in RED zone.

Displays the message CONTINUE if current reading and previous are in GREEN zone or one is in YELLOW and Another one is in GREEN zone.


Collecting Data Using Fixtures

There are 2 steps for data acquisition through fixtures.

Mastering

Measurement

It is expected that you know the following concepts before initiating mastering or measurement:

Switch – In order to dump the reading it can be achieved by pressing H/W switch connected to Advantech card of your machine or the Start/Stop button provided on the screen.

Single Switch – Single switch can be used for dumping readings for all parameter in one click.

Multiple Switch – for every parameter one switch is assigned .one click of switch corresponding parameter readings will be dumped.

Dynamic parameter – Parameter can have reading type MAX, MIN, TIR, AVG

MAX – Maximum reading for the parameter.

MIN – Minimum reading for the parameter.

TIR – Take Max and Min and take difference between max and min.

AVG – Find Max, Min and take average of max and min.


Data Capturing

Reading – ((Calculated as per formulae of parameter  + Calibration Value) * Gain Factor) + Master Value

In case of Dynamic parameter caption of switch will be "Stop" and no readings are captured from connected probes. For capturing readings press on Stop button or press H/W switch caption of button will be changed to Start and system will start capturing readings from connected probes and it will first evaluate formulae by considering probe readings then will calculate reading as per Reading explained above. After calculating reading, the system will compare this reading with the previous calculated readings and then the latest readings will be shown in current reading text box .On click of Start button system will dump reading of parameter(s) into database and caption will be set back to Stop and no readings are captured.

In case of Static parameters caption of button will be always Start and system is continuously capturing probe values and by using this it will evaluate formulae of parameter and then it will calculate reading as per Reading as explained above. Reading calculated is final reading and it will be shown in current reading text box. On click of Start button or press of H/W switch system will dump readings into database the caption of button will be Start.


Coloring of Current Reading text boxes

For a reading within control limit, the reading textbox color will be Green.

For a reading out of control limit and within specification limit the reading textbox color will be Yellow.

For a reading out of specification limit, the reading textbox color will be Red.


Coloring of Trend

If all the readings are within the control limit then the trend color will be Green.

If any one of the readings is an out of control limit and within specification limit then the trend color will be Yellow.

If any one of the readings is out of specification limit then the trend color will be Red.


Warning Messages

If reading for any particular parameter goes out of control limit then message will display ‘Beyond Control Limits. Accept ? ‘  If user selects No then reading for that parameter will not be dumped.  If user selects yes then reading for that parameter will be dumped.


Message For Reminder

As per sample frequency entered for a parameter in WOQAP system will flash reminder message "‘Time to Take Reading", if in case readings are not captured during specified period.


Charts

In the Fixture Measurement screen, charts for the selected parameters will appear on the right hand side. If there are more than one parameter for the Job, then initially you view the charts for first two parameters. You can navigate through the charts using the Up and Down arrow buttons on the form. The Up and Down arrow buttons will be enabled or disabled depending upon the no of parameters and the parameter for which chart is displayed (First/Middle/Last). You can double click on the particular chart to see it as enlarged one.

If the sampling technique is Sampling, then the online chart shown is X Bar R chart. If the sampling technique is 100% inspection, then online chart plotted is X-MR chart


SPC Calculation on Sample Completion

The control limits for the parameters are calculated on the completion of sample, if the Repeated Calculation option is checked for the selected parameter in Work Order QAP, then the standard deviation, Cp, Cpk, Pp and Ppk values are calculated at the end of every sample.

If Sampling Technique for a parameter is 100% Inspection (as selected in WOQAP), then moving range and mean values are calculated for that parameter. These values are used to calculate the Control Limits, standard deviation, Cp, Cpk, Pp and Ppk values for the parameter. The online chart shall display the X MR chart for the parameter.

If Sampling Technique for the parameter is Sampling (as selected in WOQAP), then X Bar (i.e. mean) and Range values are calculated for the selected parameter. These values are used to calculate the Control Limits, standard deviation, Cp, Cpk, Pp and Ppk values for the parameter. The online chart shall display the X Bar R chart for the parameter.


Reading No. Display

Current reading number will be displayed at bottom left hand side of screen. it will be as Current reading number / Sample size.


Mastering

The Mastering screen displays all the parameters of selected job that are mapped to fixture in Fixture Mapping screen. For every parameter Current Reading, Master Value and Gain Factor is displayed. At the bottom of screen it shows the Legend that is applicable to Current Reading. Start button will be used for dumping reading and Close button is used for closing mastering screen.

In this screen you are allowed to do Mastering by clicking on Start/Stop button or by pressing H/w switch. On click Mastering value will be calculated as difference between Current Reading and Master Value for each parameter displayed. Mastering value for each parameter will be stored in database. Gain factor for each parameter will be enabled user can set gain factor and then click on Start/Stop button or press H/W switch to set Gain Factor. On setting Gain Factor system will automatically close Mastering screen and will launch screen for Measurement.


Measurement

The Data Capturing and Data Analysis screen is launched when you click Measure on the Reading tab of the Local Monitoring screen.

Use this screen for:

Recording data for multiple Variable parameters for multiple jobs manually or automatically.

- Viewing Trends which occur during capture of data.

- Viewing Charts for Data Analysis.

- Viewing Control Charts along with the Statistical Analysis for single Parameter

- View Bar Display

- Viewing Cp/Cpk or Pp/Ppk value (Dash Board)

This screen has six tabs –

Readings tab

Charts tab

Control Chart tab

Bar Display Tab

Dashboard tab

Component Tab

Bar display, Dash Board tab and Component tab will get display depending upon the Configuration setting.

After measurement screen get launch and job is of Esya Instrument, request will send to Instrument by using the Instrument address of the parameter, for collecting the data after each 20 sec. During dumping a data, system will check send & received command address is same or Not if it is different the log file will get updated for send & received command address.

Data will get stored only when the reading number is different than earlier. Example – Instrument return COYR1+000.487, system will check Reading No 1 is last reading No for selected parameter, If yes then system will not dump the data/reading If no data will get stored in the respective parameter.

Close button will get disable during sending a request. After finishing the request for all parameter Close button will get enabled.


Digital Display

This screen for measurement will display all parameters of selected job that are mapped to the fixture in the fixture-mapping screen. Screen caption shows current fixture name. For every parameter Current Reading is displayed in Current Reading text box. On line chart is plotted right hand side of screen, and at bottom of screen it shows Reading Number, legend that is applicable to Current Reading, Trend for sample reading, Start, Next and Close buttons. Start button will be used for dumping reading and Close button is used for closing mastering screen. Next button will be used for moving to next fixture in case of measuring type selected of job is By Piece. Next button will disabled in case of measuring type selected of job is By Fixture


Bar Display

Screen for measurement will displays all parameters of selected job that are mapped to fixture in fixture mapping screen. Screen caption shows current fixture name. Screen will display all part parameters along with horizontal bars and text box showing current reading will appear on the screen one below the other. This screen doesn’t show online chart. Each bar on screen shows mark for LSL, USL, and Nominal value. At bottom of screen it shows Reading Number, legend that is applicable to Current Reading, Trend for sample reading, Start, Next and Close buttons. Start button will be used for dumping reading and Close button is used for closing mastering screen. Next button will be used for moving to next fixture in case of measuring type selected of job is By Piece. Next button will disabled in case of measuring type selected of job is By Fixture

Coloring of the bars is based on the value of the reading. For further information of Coloring Of Bars.


Coloring Of Bars

Coloring of the bars will be based on the following conditions.

IF reading within LSL & USL then

IF reading <UCL and reading >LCL then

IF reading > nominal value then

    Bar will be colored as green from

      	                      Nominal value to right side

ELSE

     Bar will be colored as green from

                       Nominal value to left side

END

ELSE

IF reading > nominal value then

    Bar will be colored as yellow from

                            Nominal value to right side

ELSE

     Bar will be colored as yellow from

                       Nominal value to left side

END

END

ELSE

IF reading > nominal value then

    Bar will be colored as red from

                 Nominal value to right side

ELSE

     Bar will be colored as red from

            Nominal value to left side

 END

 END


Decision

Use this screen to maintain detailed information about online and offline decisions taken for readings which are out of control limits. There are two tabs: the Take Decision tab and the Corrective Action tab.

At the time of manual recording of readings, in the Local Monitoring screen you may take online decisions. If level two trend is raised and the readings are out of specification limits, you must take a decision and corrective action immediately. If level one trend is raised and the readings are out of control limits/runs up mean then you must take corrective action immediately.

In the Local Monitoring or Global Jobs screen:

Click Take Decision on the Pending Decisions tab to enter decisions offline.

Click Corrective Action on the Pending Corrective Action tab. to enter corrective actions offline.

Click Take Decision on the Sorting Analysis tab to enter decisions offline.


Corrective Actions

When the non-conformities are detected you are expected to take corrective actions.  The list of jobs in which the non-conformities are detected is displayed in the Corrective Actions screen.

Click on the Add button to add a corrective action record to the database. You may then assign the responsibility of taking the corrective actions to either the entire department or the individual user. Clicking the suitable radio button in the Responsibility Assigned To group box may do this. You may then select the Root Causes, Responsibility, Corrective Action Taken By, and Target Date. You may add then the comments or describe the corrective action details in the Corrective Action Remarks field.


Corrective Actions Completed

The list of the parts for which the corrective action has been taken is displayed in the grid in the upper half of this screen.  Select a Part and you may click on the Add button to add the details of the corrective actions taken for a part. Set the date on which the corrective action was completed in the Completion Date. Add any remarks, comments in the Remarks field. Click on Save button to save the record.


Defining Masters

Use the Configuration Menu to enter master data into the system. Create the masters in the sequence provided in this menu.

The following are the masters in PROQMS, which are created before activating the QAP.

Department

Define departments.  (See Department Master)

User

Define information about the members of the organization.  (See User Master)

Supervisor

Define supervisors. (See Supervisor Master)

Role

Define different roles in the organization. (See Role Master)

Part

Define manufacturing parts. (See Part Master)

Process

Define various processes of manufacturing part.  (See Process Master)

Part Parameter

Characteristics of a part, that can be measured or counted for recording and analysis. (See Part Parameter Master)

Parameter

Define the various parameters for the Tools that have to be monitored. (See Parameter Master).

Location

Define locations which will be used in defining the Machine master and Instrument master.  (See Location Master)

Local Machine

Define local machines. (See Local Machine Master)

Machine Type

Define various machine types.  (See Machine Type Master)

Machine

Define details of different machines. (See Machine Master)

Instrument Type

Define type of instruments used for capturing quality data.  (See Instrument Type Master)

Instrument

You can define various instruments used for capturing quality data.  (See Instrument Master)

Zone

Use this option to define Zone, Zone Description, Zone Sequence No, and Tray in Zone, which will use for how much time tray, is present in specified zone.  (See Zone)

Parameter Category

Use this option to define different parameter for a Parameter Category which has LSL and USL. This will be used for plotting chart of tray.  (See Parameter Category)

Zone Parameter

Use this option to configure Zone, Parameters and its Captured Reading Time, which will use while plotting a chart.  (See Zone Parameter)

Tray Time Entry

Use this option to configure Tray in Date, Time and Tray Number, which will use while plotting a chart.  (See Tray Time Entry)

Instrument Calibration

You can add different Instrument No, Cal Step Code, LSL, and USL for creating relationship of Instrument with Calibration Step Code with LSL & USL. (See Iinstrument_Calibration)

Dashboard Master

Define various plants, divisions, units and cells. (See Dashboard_Master)

Assign Dashboard

Assign the dashboard levels to users. (See Assign_Dashboard_Levels)

Shared Folder Path of Excel file

Provide details about the path of Excel or CSV files. (See Shared Folder Path of Excel file)

Email Escalation Master (Dash Board)

Create Email Escalation hierarchy like President, General Manager and Unit Manager and then assign unit to Unit Manager. (See Email Escalation Master)

Country

Define various countries. (See Country Master)

Customer

Define customer information.  (See Customer Master)

Customer Part

Define the Part Code used by the Customer for a part defined in the Part master. (See Customer Part Master)

Part Machine

Define part–machine relation so that you can gauge the performance of the part and the machine and the capacity of materials it produces per hour.  (See Part-Machine Master)

Unit of Measurement

Define details of unit used for measurement of part parameter.  (See UOM Master)

Trend Messages

Map Standard Messages with Customized Messages for the Trends raised. (See Trend Messages)

Root Cause

Defined root causes that can be used later in Corrective Action screen.  (See Root Cause Master)

Root Cause Detail

Define sub causes for root causes defined in the Root Cause Master. (See Root Cause Detail)

Shift

Define shifts  within which the users of the system are logged on.  (See Shift Master)

GRR Result

Configures GRR Result based on Min & Max Percentage.  (See GRR Result)


Corrective Action Trend screen

While taking readings through fixtures, trends may be raised. If a trend is raised then the user has to take a corrective action based on the settings done in the Trend Settings screen.

You can select the Root Cause, Sub cause from the respective drop down list box. If trends are raised at level-2, then corrective action needs to be compulsory taken, but at level-1 corrective action may or not be taken. Click on Ok button to save the corrective action taken and close corrective action trend screen. Click on Cancel button to close the corrective action screen, provided trends are raised at first level and not at the second level.


Defining Work Order and Job

Work Order & Job Creation is included in the product installed, it allows defining work order & job

Click on Add button to create a work order and Job. You may select the Part Number for which the work order is being created from the Part drop down list box. Select Process from the Process drop down list box and Work Order is displayed i.e. PartNo_SystemDate. Enter the quantity of the parts to be manufactured in the Target Quantity text box. If the job is created for multiple fixtures then either of the options, ‘By Piece’ or ‘By Fixture’ option can be selected. You may click on the Save button to save work order and job. If job already exist for the WorkorderNo, part, process and machine then it will display, message stating that Job already exists, and if you still want to create another work order with the same date then it would be created and displayed as follows: - PartNo_systemdate_1.

If selected Part and Process are not mapped to fixture(s). Then created job will be available in Local Monitoring. If selected Part and Process are mapped to Fixture then created Job will be available for monitoring in Fixture Monitoring and Local Monitoring screens. If mapping is done with more than one fixture then all mapped fixtures are shown in Fixture Details grid and Measurement group box is enabled. You may select Measurement type and change the Sequence No. Of Fixture.

Measurement type can be

By Fixture

By Piece

By Fixture – means you are allowed to take one set of reading form current fixture. Then automatically next fixture in sequence will be available for capturing readings.

By Piece – means that you can take as many readings as you want on one fixture continuously. When you want to move to the next fixture in sequence for data capturing you have to select option for it on measurement screen.


Global Monitoring

This screen displays details for the selected Job and Parameter such as Station No., Process Code, Work Order No, Batch No., Part No., Machine No., Parameter Code and Parameter Type will be display in the respective text boxes of Global Monitoring screen.

Grid will be populated with all sample details for the selected job and part Parameter such as all readings taken, reading Date, reading Time, Operator Code, LSL, USL, LCLx, UCLx, Mean and Reading Mode for each sample.

You can delete any sample by selecting it and clicking Delete button. Confirmation message will be displayed ‘Are you sure you want to delete this sample?’ If you click no then sample will not be deleted.  If you click yes and fixture is not associated with the selected job then the selected sample for only selected parameter will get deleted. If fixture is associated with the selected job any other parameters of the selected job have the sample number same as that of the selected one then only those samples for all those parameters will be deleted. Control limits will be calculated, based on Repeated Calculation being checked in Work Order QAP for that parameter i.e after every number of samples specified. If repeated recalculation is not selected then the control limits will be calculated only when the total no of samples taken equals the number of samples for limit calculation defined in the Work Order QAP.

Grid under Reading tab (i.e. Parameter grid) will display the details such as Job No., Part Code,Parameter Code, its Description, Last Sample Date and Last Sample Time, No. of Samples/Readings and Type for all parameters defined for all selected Job. If parameter type is Variable then type will be V. If parameter type is Attributive then type will be A. All checkboxes for all parameters in the Parameter grid will be unchecked by default. User will be allowed to select more than one variable type of parameters by checking the checkboxes for required parameters before clicking on View button. This multi select property is not applicable for attributive type of parameters.

If the parameter selected is having Precontrol Chart set from WoQap/JobCreation then multiselection of parameters for measurement is applicable.

When component Number flag is assigned  and user try to click on Delete button system will display message as ‘Cannot Delete, Component number is assigned’.

Single Instrument Multiple Parameter –

If Job is of Single Instrument and user try to delete the sample of one parameter then
s/w will delete all the parameters of selected sample of that job.

Reading Change Facility –

Edit and Cancel button will get visible only for the user whose role is ‘INST’

In the Grid if reading has gone out of Specs Limit then reading can be display in Red color.

First user should select a row for which user want to change the reading & then click on Edit button, caption of the edit button change to Save & Cancel button will get enabled and reading column is available for editing. User can edit the reading and click on save button.


Backup

It is very important to take a backup of the database at regular intervals. This ensures that no data is lost in the event of any unforeseen circumstances like machine failures, disk crashes, database crashes etc. The Backup option makes a copy of database that can be used in future.

The last three backups taken will be maintained by the system.

When the question "Ready for taking backup?" is displayed, click Yes to proceed.

On confirmation, the message "Backup process in progress…" is displayed.

On completion the message "Backup completed successfully" is displayed.

 A copy of the database is made in the Backup directory. The name of the Backup database will be the current date appended to the database name e.g. Proqms2-27-May-2003.

For Access Database : The database name will have the extension .mdb

For Oracle Database : The database name will have the extension .dmp. The logfile will also be created in the same directory with the same database name and extension .log. You can view the contents of the logfile to check the status of the backup process.

For SQL Server Database: Backup will be taken on the server in a backup device. The name of this device will be the current date appended to the database name. This will be created on the server machine itself. You can view the device from the Enterprise manager on the server. This file can be transferred to Detachable storage devices manually. For every backup a new device will be created.

If you attempt to take a backup on the same date more than once, the question "Backup already taken, do you want to over write it?" is displayed. Click Yes to overwrite the backed up database. Clicking on No displays the message "Backup canceled".

See Also : Restore


Restore

The Restore option is used to restore data from the Backup database when the need arises. Select File/Restore from the Main Menu. If a backup database does not exist, the message "No files found in backup directory" is displayed.

When backups exist in the backup directory, select the database name from the drop down list which is displayed.

For Access Database : The databases with the extension .mdb will be displayed.

For Oracle Database : The database names with the extension .dmp will be displayed.

For SQL Server Database: All devices on which backups are taken will be shown in the list. For any selected device restore will be carried out. Before restore, the original device file should be on the same location from where it was taken. If the device files are copied to storage devices and deleted from the hard drives, they should first be restored to the hard drives and then Restore should be carried out.

After the database is selected, the question "Overwrite the existing database?" is displayed.

On confirmation, the message "Make sure all users are logged out." is displayed.

After you have ensured that all users have logged out, click OK to proceed.

On completion of the restoration process, the message "Restore process completed" is displayed.

The existing database will have been overwritten by the selected database.


Job Closure

You can close selected job from Local Monitoring /Global Monitoring /Fixture Monitoring screens .On close you have to enter produced quantity for a job. Message will be displayed on successful closure of job. All data related to closed jobs will be transferred to history files. History reports are available for viewing this data.

While closing the job from Local Monitor / Global Monitor and creating the Job internally then s/w will ask user 'Do you want to retain the old data in the Latest Job' If user say Yes then software will copy the last reading and sample in the latest Jobs for continuity purpose and control Limit also.


Work Order Closure

You can close WorkOrder, only if all jobs of a WorkOrder are closed. Message will be displayed on successful closure of WorkOrder. All data related to closed WorkOrder will be transferred to history files.


Purging

Over a period of time, there may be a lot of data accumulated in the database which is not used on a regular basis. This may relate to data pertaining to closed work orders, work orders completed during the previous years etc. The Purging option is used to move data out of the currently used database into a history database. This database will contain history records for closed work orders.

Before Purging, make sure all users have logged out and Backup has been taken of the database. Please note that the intermediate tables used during Purging must be empty before you start the Purging process.

When the question "Are you sure you want to purge history records?" is displayed. On confirmation, the screen for entering the date prior to which data is to be purged is displayed. On entering the required date, the message "Make sure all users are logged out." is displayed. Click  OK after ensuring that all users are logged out.

The question "Are you sure backup is taken of the database?" is then displayed. On confirmation, the directory selection screen for storing the purged records is displayed. Select the required directory.

On completion of the Purging process the message "Purging is completed." is displayed.

The name of the History database will be the current date appended to "ProqmsPurging" e.g. ProqmsPurging27-5-2003.

For Access Database : The database will have the extension .mdb.

For Oracle Database : The database will have the extension .dmp.

For SQL Server Database: Purging will be taken on the server in a backup device. The name of this device will be created will be the current date appended to the database name. This will be created on the server machine itself. You can view the device from the Enterprise manager on server. This file can be transferred to Detachable storage devices manually. For every purged database a new device will be created.

Steps In Purging

Data to be purged is transferred to intermediate tables within the database.

The new history database is created having tables of the same structure as the intermediate tables.

Data is transferred to the history database.

Data is deleted from the actual tables and intermediate tables.

If at any stage during the Purging process, an error is encountered, the database is maintained at the state in which it was before the process began.

See Also: Uploading


Uploading

Uploading is used to reload data which has been transferred to history tables using the Purging option. If for some reason, data pertaining to closed work orders is required in the existing database, it can be done using Uploading.

Before Uploading, make sure all users have logged out and Backup has been taken of the database.

Select File/Uploading from the Main Menu. The screen for selection of the database from which data has to be uploaded (i.e. Purged database) is displayed.

For Access Database : Select database with extension .mdb.

For Oracle Database : Select database extension .dmp.

For SQL Server Database: All devices on which purged databases are taken will be shown in the list. For any selected device uploading will be carried out. Before uploading, the original device file should be on the same location from where it was taken. If the device files are copied to storage devices and deleted from the hard drives, they should first be restored to the hard drives and then uploading should be carried out.

After this has been done, the message "Make sure all users are logged out" is displayed. Click  OK after ensuring that all users are logged out.

The question "Are you sure backup is taken of the database?" is then displayed. On confirmation, the Uploading process begins.

After completion, the message "Uploading is completed." is displayed.

If an attempt is made to upload data from the same database more than once, the message  "Data has been already uploaded for the selected file" is displayed.

Steps In Uploading

Data to be uploaded is transferred to intermediate tables within the database.

Data is transferred to the actual tables after data integrity is verified.

Data is deleted from the intermediate tables.

Some related data might have been deleted after Purging and this would cause a problem at the time of Uploading. If at any stage during the Uploading process, an error is encountered, it is displayed on the screen and written into a logfile. This logfile will list all errors encountered. The message "Uploading not successful. Refer to the logfile" is displayed along with the name and location of the logfile.

The Administrator must view this file, enter related data and then execute the process once more. The log file will be created in the same directory where the Purged database exists. The name of this file will be ProqmsUploading with the current date appended to it. It will have the extension .log.

In case of any error, the database is maintained at the state in which it was before the Uploading process began.


Email

Select File/E-mail from the Main Menu to e-mail a report.

For E-mail, the machine must be connected to a network  which has mail facility. A report must be active to send  e-mail. The  default mail client is invoked with the report as an attachment.

 Enter the e-mail address and click Send to send the report.


Options

This option will launch the Options dialog box. Here in this form there are 3 tabs in this form.

The 1st tab is the General Tab here you can set the Text that will be displayed in the Header and Footer Section of the chart. These details will be displayed when the chart is plotted.

The 2nd tab option is that of Homogenization, by default the Homogenize option is disabled. On selecting the Visual Homogenization option it will enable the Homogenize option in the menu. There are 2 more options provided such as

Delete Non Conformities

Delete Non Conformities and Recalculate Limits

The 3rd option is the Filter option. Here you can specify the maximum points to be displayed on the chart. There are 3 radio buttons provided in the tab

All Points - The chart will be plotted for all the readings

First Points – This option enables you to display the first set of readings

Last Points -This option enables you to display the last set of readings


Rework Job Details

This Option displays the Rework Job Details Screen. This screen will be launched when internal rework option in Job Details Screen is enabled. This screen displays the Job, which have been sent for rework. Various details assigned with the job that are displayed are the Job Start Date, Job Start Time along with the Machine No.

The user can select a job and assign it for rework.


Defining Part in Standard QAP

For defining a new Part, Select Root node i.e. StdQap, Click on the Add toolbar button or menu item. Part combo will be displayed with the distinct part codes from Part screen. Select part, Description Textbox will display part name for the selected part. Process combo will be enabled. Process combo will be displayed with the processes from Process screen but with only those, which are not yet attached to that part.

Select process. Prepared By field will display the logged in user. Save the record. After saving the record, Part and process defined will be added to tree view .On selection of a particular process their details will appear in Right Hand Side of the details screen.


GRR Mapping

Use this option to map an instrument to a part and its corresponding parameters for taking measurements for the Gauge R & R study. You can also view the number of trials done for a parameter along with the date and time of the last trial. Once all trials for all parameters have been completed then that study is not displayed on this screen.

 The local machine no. (i.e. Station No.) shall be considered by default for mapping details for an instrument.

Click Add to add a new record. Select Instrument Code from the drop down list displayed from the Instrument master. Study Date displays the current date. Select appropriate date not less than the current date, if required. Select Part Code from the drop down list displayed from the Part master. Select Parameter Code from the drop down list. This list contains only those parameters which have not been mapped to the selected instrument code, study date, part code and local machine.

Enter the Master Value. Specify the Reading Mode – whether Automatic or Manual. Enter Tolerance and Process Variation. At least one of these two fields must be entered.

Select Decimals, No. Of Parts, No. Of Operators and Trials Per Operator from the drop down lists. Their default values are 0, 10, 2, and 2 respectively.

Click Save to save the record. You can map only as many parameters as are specified for the interface code of the instrument.

Once a parameter has been mapped for an instrument, No. Of Parts, No. Of Operators and Trials Per Operator are set for all subsequent parameters.

Use Pp Value, LSL Value and USL Value to calculate GRR value using Pp method.

Click Modify to make changes. You can modify Decimals, Reading Mode, Master Value, No. Of Parts, No. Of Operators, Trials per Operator, Tolerance, Process Variation and Study Date only if trials have not begun for the selected Instrument Code, Part code and Parameter code. If some trials have been taken for the mapped part and parameter then you can modify only Decimals and Reading Mode. If  you change No. Of Parts, No. Of Operators or Trials Per Operator for a parameter, the same change is made for all other parameters mapped to that instrument code.

Click Measure if you wish to go to the Gauge R & R Measurement  screen to record readings.

Click Delete to delete a record. You can delete a record for a Local Machine only if trials have not begun for it. For deleting a record, you must specify the Instrument Code, Study Date, Part Code and its corresponding Parameter by selecting them from the respective drop down lists.


GRR Measurement

This screen gives you a facility to capture the readings for an Instrument both Manually and Automatically. You can take simultaneous readings for all the parameters mapped to an instrument. Details of the Channel No., Serial/Parallel Port, and Port No. for the Instrument are also provided.

Reading Mode and Station No. are displayed from the Gauge R & R Mapping screen. The current user is displayed as the Operator Code.

For Manual Reading Mode, the Operator Code is used to identify by whom the readings were taken. Channel No. and Port Details (whether Serial Port or Parallel Port, Port No.)  are not defined.

For Automatic Reading Mode, whether Serial Port or Parallel Port is displayed from the Interface master of the Instrument. Port No. and Channel No. are displayed from the Instrument master.

A grid is provided for taking readings. The first column displays Part numbers from 1 to ‘n’, where ‘n’ is the number of parts specified in the Gauge R & R Mapping screen. The balance column/s of the grid are for readings. The number of columns for readings is equal to the number of parameters mapped to the instrument. The readings columns display the parameter names as the headings. e.g. If for the Dumore instrument, 3 parameters ID1, ID2, ID3 are mapped  in the Gauge R & R Mapping screen, then the Gauge R & R Measurement  screen is launched with the provision of three column for the reading values. The reading value column headers have names as ID1, ID2, and ID3 respectively.

Click Modify to make changes. You can modify Channel No., whether Serial Port or Parallel Port and Port No. only if the reading mode is Automatic.

Taking Measurements

At a given time, only as many operators may log on as are specified in the Gauge R & R Mapping screen. An operator may take only as many trials as are specified in the Gauge R & R Mapping screen.

In Manual mode, you can enter readings directly into the grid for a particular part and parameter. You can modify readings only until they are saved.

In Automatic mode, select the Part No. for which you wish to take the reading by clicking on the corresponding row. Click Start. A question is displayed whether to proceed with readings. On confirmation, the reading is displayed on the respective parameter cell corresponding to the selected Part No. when you press the switch on the instrument. Repeat the same steps for the other parts. Readings displayed in this way cannot be modified.

Click Save to save readings after all readings for all parts and parameters have been taken. You cannot save only a part of the readings. A reading cannot be modified once it is saved.

Click Close to return to Gauge R & R Mapping  screen. The Last Trial Date, Last Trial Time and Trials Done are updated for the parameter(s) for which the trial was taken.

See Also: Gauge R & R Data Analysis


The Reading Tab
The Reading Tab (Local Monitoring)

When this screen is launched, all jobs for the local machine are displayed in descending order of Job No. on the Reading tab. If the job has been created using Work Order Maintenance and Job Details screens then the caption of the first column of Job grid will be Work Order No. instead of Job No.

‘V’ indicates Variable type parameters. ‘A’ indicates Attributive type parameters. By default, the checkbox for the first job is selected. You may select more jobs if you wish to take readings for multiple variable parameters. As you select jobs, parameters for those jobs get displayed below for selection.

Grid under Reading tab (i.e. Parameter grid) will display the details such as Job No., Part Code,Parameter Code, its Description, Last Sample Date and Last Sample Time, No. of Readings and Type for all parameters defined for all selected Job. If parameter type is Variable then type will be V. If parameter type is Attributive then type will be A. All checkboxes for all parameters in the Parameter grid will be unchecked by default. User will be allowed to select more than one variable type of parameters by checking the checkboxes for required parameters before clicking on Measurement button. This multi select property is not applicable for attributive type of parameters.

If an instrument gives multiple parameters, selection of one of these parameters automatically results in selection of all parameters. De-selection is done in the same way.

Please note, that you can select only one attributive parameter. If the parameter selected has Precontrol Chart set from WoQap/JobCreation then you can select one parameter only.

If the parameter selected has Pre-control Chart set from WoQap/JobCreation then user can select more than one parameter i.e. non-precontrol variable parameter and pre-control parameter.

You may also deselect jobs.  At least one job must be selected to view reports and charts.

To change the mode of taking readings – whether Automatic or Manual, click Modify. For Attributive parameters the reading mode must always be Manual. Click Save after changes have been made.

If you change the mode for any variable type of parameter and save it then the same mode will be saved for all other variable type of parameters displayed in the parameter grid.

Single Instrument for Multiple Parameter –

If Job is of Single Instrument then user tries to select single parameter then all the parameters should be selected for that job even also if the parameter has a different instrument type and if the user unchecks any one parameter then all the parameters for that job should be unchecked.

Click Measure to launch the Measurement screens.

For Variable parameters, the Data Analysis and Data Capturing Screen  is launched. If 100 % Inspection option has been selected for the parameter at the time of job creation, then Last Sample Date and Last Sample Time are updated after each reading.

If Sampling option has been selected, No. Of Readings, Last Sample Date and Last Sample Time are updated after each sample.

For Attributive parameters, the Measure For Attributive Type screen is launched. No. of Readings, Last Sample Date and  Last Sample Time  are updated after each reading.

When you take readings using the Data Analysis and Data Capturing Screen if some readings for a particular sample are not within control limits or specification limits, you are asked whether you wish to take a decision about what should be done with the sample. On confirmation, the Decision screen is displayed.

Where the average of the readings is also not within limits, you may enter decisions and corrective actions. Records for which you do not take a decision are displayed on the Pending Decisions tab. Records for which you do not take corrective action are displayed on the Pending Corrective Action  tab.

Where the average of the readings is within limits, you may enter corrective actions only. Records for which you do not take corrective action are displayed on the Pending Corrective Action  tab.


The Pending Decisions Tab
The Pending Decisions Tab (Local Monitoring)

Select a single parameter and click on the Pending Decisions tab to view all the pending decisions for the selected job and parameter. Parameter Code, UCL, LCL, Mean, Sample Date and Sample Time are displayed. Click Take Decision to display the Decision screen. After a decision is taken, the record is not displayed on this screen.


The Pending Corrective Actions Tab
The Pending Corrective Actions Tab (Local Monitoring)

Select a single parameter and click on the Pending Corrective Action tab to view all the pending corrective actions for the selected job and parameter. Parameter Code, Sample Date, Sample Time, Levels and Trend are displayed. Click Corrective Action to display the Corrective Action screen. After corrective action is taken, the record is not displayed on this screen.


The Sorting Analysis Tab
The Sorting Analysis Tab (Local Monitoring)

Select a single parameter and click on the Sorting Analysis tab to view the records for which you select the Sorting option in the Decision screen. Parameter Code, Sample Date, Sample Time, No. Of Units and Decision Taken By are displayed. Click Take Decision to re-display the Decision screen. After a decision is taken, the record is not displayed on this screen.


The Readings Tab
The Readings Tab (Measurement)

This tab displays all parameters which have been selected for measurement from the Local Monitoring screen. Since parameters are for multiple jobs, job details are also displayed.

Recording Readings Manually

Enter readings in the Reading field. The background color is set based on limits specified for the parameter:

Green - The reading is within control limits.

Yellow - The reading is out of control limits.

Red - The reading is out of specification limits.

The reading displayed is the setting value plus actual reading entered.

For a manned station, if the reading is entered manually, it is saved when you press Enter.

The current reading serial number in the current sample is displayed as the Reading No.

Select or deselect the Chart column depending on whether you wish to view charts for the readings of the parameter on the Charts  tab. Upto four Critical parameters are selected by default. If no critical parameters exist, the first four parameters are selected.

Display Job No. check box is provided in Reading Tab. When user selects Display Job No. then Job NO. can be seen in the grid else can not be seen. Size of the Part and Parameter column can be changed.

Sample Frequency

Screen should check that readings for parameter are taken as frequently as defined in Sample Frequency in Standard QAP. If readings are not taken within time and in company setting user checked Display/Capture Time to Take Reading then screen should notify that readings are not taken and its time to take reading. Notification will be different in manned and unmanned station. In case of manned station message will be displayed on screen. And in case of unmanned station message will be inserted in message table for all supervisor users. Supervisor user is one whose role is defined as "SUPER ". Sample frequency is made available for 100% inspection and sampling technique. Time to take reading message will not get display or recorded if check box of Display/Capture Time to Take Reading is not checked.

Deletion of the reading/Sample-

When the user presses the key F6 for any of the parameters for which readings are entered, then it would ask user  "Are you sure you want to delete this reading?" with Yes/No. If the user clicks on No the reading is not deleted. If the user clicks on Yes then one reading deleted for that parameter

While deleting the sample it will check corrective action has been taken or not, if corrective action has been taken then it will display. "Corrective action has been taken. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on Yes the sample is deleted.

While deleting the sample it will check for Trend raised. If trend raised then it will display. "Trends have been raised. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on Yes the sample is deleted and trend will get reset.

When sample is completed  & user Press F6 then system will prompt the message "Are you sure you want to delete this sample" & if user press Yes then

- It will check corrective action has been taken or not, if corrective action has been taken then it will display. "Corrective action has been taken. Do you want to delete the sample? " If the user clicks on No the reading is not deleted, if the user clicks on yes the sample for all parameter is deleted & then grid will show 0 / Sample Size

- If Trend raised then it will display. "Trends have been raised. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on yes then sample for all parameter get deleted & then grid will show 0 / Sample Size. If user press No then No sample for all parameter get deleted

Deletion of the reading/Sample – For Single Instrument Multiple Parameter

When all parameter have same reading serial no and sample is not completed i.e. in case of individual reading & user Presses F6 then system will prompt the message "Are you Sure Do you want to delete reading only for the selected Parameter?"

If user Presses 'Yes' then reading for selected parameter for current Reading serial No will get deleted & Reading serial No get updated for a parameter.

If user Presses 'No' then system will prompt a message - "Are you sure Do you want to delete reading for all parameters?" If user presses 'Yes' then reading for all parameters for current Reading serial No will get deleted & Reading serial No get updated for all parameter. If user presses ‘No’ then record will not deleted.

Job is of Single instrument multiple parameter having 3 Parameters. Sample Size is 3. First two parameter has taken 2 reading i.e. 2/3.  Third Parameter has taken 1 reading i.e. 1/3.  User tries to delete the reading of 3rd parameter. Message should display ‘Can not delete reading for the selected parameter as parameter is of Single Instrument.’

Remark for reading –

After entering the reading, user can enter the remark for reading. Icon for Remarks – Click on this column i.e. on icon it will display the Remarks for Reading Screen with latest Sample No. and Reading No. If No Readings are taken for the parameter and try to click on icon it will display the message as  ‘No readings taken for the parameters’.

If a remark is present then it will show the remarks for the selected reading else it will show the Reading Sample screen.

Single Switch Facility –

If Job is of single switch, i.e. there will be different instrument attached to different parameter, and different port for each parameter. All the parameters data will be dumped on the press of a single switch and if any one parameters data is not coming from the respective port then all the parameters data will be ignored and it would not update the database.

   Do not accept the reading which are 20% [Configurable] more than specs limit-

Suppose if LSL value is 5 and USL value is 15 then 20% of USL Value- LSL value would be 3 and 20% of USL value- LSL value would be 17, so the permissible readings should between 3 and 17 any reading that is not within in this range should not be dumped to the database, but should be stored in the log file and the acknowledgement yellow light will not glow and the reading will be shown on the screen without incrementing the serial number.

Angle Parameter -

After user click on Measure button of frmMonitor screen, frmMeasurement screen will display. If parameter UOM is angle then Reading column of grdReadings show value in degree otherwise its show in decimal.

In manual mode enter value in decimal & pressing enter button on that Reading column it will convert to degree if parameter UOM is angle otherwise it remain as decimal.

In automatic mode when reading comes from port or from channel it will show the value in angle if parameter is of type Angle else value will be display in decimal

   Display current sample No on Reading Tab–

If one of the parameter having sampling technique is ‘Sampling’ then column header name is "Sample No", will display just before the "Reading No" column.

If parameter-having sampling technique is ‘Sampling’ then "Sample No" column will show the current sample no.

If all selected parameter having sampling technique is "100% Inspection" then column header name change from "Sample No" to "Count" & is position is just before the "Reading No" column. Reading No column will not be visible in case of 100% Inspection.

If parameter having sampling technique is ‘100% Inspection’ then "Count" column will show the count of all reading,

After deleting the reading or sample from Reading Tab or Chart Tab, then Sample no./Count should get updated.

LG Network Monitoring–

In case of LG Network Monitor When user launch measurement screen from Local Monitor with job i.e. already selected in another instance of ProQMS then system should prompt the message 'Selected job is already running in another instance of same PC'

In case of LG Network monitor when data receives in the Measurement screen and same parameter is launched in the global Monitor screen then Measurement screen should sends the signal to Global monitor screen for refreshing the reading and chart.

In case of LG Network monitor when user deletes the reading/sample or Add remarks or taken corrective action in the Measurement screen of Local Monitor and same parameter is launched in the global Monitor screen then Measurement screen should sends the signal to Global monitor screen for refreshing the reading and chart.

When user tries to delete the reading or sample from global monitor screen i.e. Global view of particular parameter and the same parameter is selected in the Measurement screen of Local Monitor then system should display the message ‘Cannot delete. Data collection is in progress’.

Calculate Control Limit (g_CalCtrlLimit = True)

When g_CalCtrlLimit flag is true and user has configured No of samples for limit calculation and Repeated Calculation is ‘Y’ for a parameter then while updating or deleting the sample system will calculate the control limit based on last No of samples for limit calculation.

E.g. Current sample is 123 and No of samples for limit calculation is 25 then system will calculate the control limit based on 76 to 100 samples. When 125th Sample finish then system calculates the control limits based on 120 to 125 samples.

When g_CalCtrlLimit flag is false and user has configured No of samples for limit calculation and Repeated Calculation is ‘Y’ for a parameter then while updating or deleting the sample system will calculate the control limit based on all samples i.e. multiples of No. of samples for limit calculation.

E.g. Current sample is 123 and No of samples for limit calculation is 25 then system will calculate the control limit based on 1 to 100 samples. When 125th Sample finish then system calculates the control limits based on 1 to 125 samples.

When user Deletes or Update readings from Global Monitor screen and g_CalCtrlLimit flag is true, Repeated Calculation is ‘Y’  then system should calculate the control limits based on last No of samples for limit calculation. When g_CalCtrlLimit is false then system will consider all samples i.e. multiples for the No of samples for limit calculation.

System will calculate control limit for XBarS, XMR chart based on last No of samples for limit calculation, g_CalCtrlLimit is true & Repeated Calculation is ‘Y’ same control limit system will use while plotting the XBarS, XMR chart


The Charts Tab
The Charts Tab (Measurement)

To view this tab, you must select at least one parameter by checking in the Chart field on the Readings tab. The number of charts displayed will be as per the number of parameters selected.

Online XbarR charts of the selected parameters are displayed. Details like part code, parameter code, Cpk value and Ppk value are shown. Readings are plotted along with date and time of readings. You can scroll through the charts.

The number of points displayed in the online chart depends on the value entered for display of online points in the Company Settings screen. For example, if the value entered is 20, the chart plots only the last 20 samples. If no value is entered, all samples are plotted.

The last customized trend message along with date and time for that parameter is displayed in a scrollable log window. You can scroll through the history of trends raised for that parameter.

For all Line Charts: To view details of all actual readings for the samples, use the mouse to move the cursor to the points plotted on the chart.

Double-Click on the chart to see the list of available charts for the parameter. Select the required chart you wish to view.

By default online chart for 100% inspection parameters will X-MR and for sampling parameters default chart displayed will be X Bar R chart. Facility to change online chart for a parameter will activated at right click on chart.

Pre Control Chart –

For parameter having pre control chart, Reading, Chart Tab will get enabled & Control Chart will get disable if all parameter having pre control chart then Cp/Cpk Tab will also get disable.

Manual Mode –

   Parameter having pre control chart display picture along with message during dumping a data.

Picture along with message will display only when after reading will get approved & there after i.e after 5 reading onwards. Picture along with message is depend upon the rule set for pre control chart.

Automatic Mode –

   Parameter having pre control chart display signal on acknowledge unit during dumping a data.

Signal will display only when after reading will get approved & there after i.e after 5 reading onwards. Signal (red/green) is depend upon the rule set for pre control chart

Display signal or picture for 1st 5 reading –

If all reading is within green zone then green picture along ‘Setting Approved’ message in case of manual mode & Green signal in case of automatic mode will get display.

One of the readings goes in Red zone then red picture along ‘Stop’ message in case of manual mode & Red signal in case of automatic mode will get display.

Only one of the readings goes in yellow zone then red picture along ‘Repeat Setting’ message in case of manual mode & Red signal in case of automatic mode will get display.

More than one readings goes in yellow zone then red picture along ‘Adjust’ message in case of manual mode & Red signal in case of automatic mode will get display

5th reading onwards –

In case of manual & automatic mode 2 consecutive reading to display signal or picture.

If one of reading is within the green zone then in case of Manual mode green picture along with the ‘Continue’ message will get display & in case of Automatic mode green signal will get display.

If one of reading is within the red zone then in case of Manual mode red picture along with the ‘Stop’ message will get display & in case of Automatic mode red signal will get display.

If both reading is within the yellow zone then in case of Manual mode red picture along with the ‘Adjust the process’ message will get display & in case of Automatic mode red signal will get display.

For a pre control chart parameter reading is approved. Reading Tab is active.In company setting, ‘No of point to display on online chart’ is 20 & user had 50 reading for pre control chart parameter. Pre Control chart will get refresh & redraw the chart i.e Last 20 readings i.e. 31 to 50 and additional 5 readings which nothing but approved setting reading. So the total reading on the chart is 25

Sample Frequency –

Screen should check that readings for parameter are taken as frequently as defined in Sample Frequency in Standard QAP. If readings are not taken within time and in company setting user checked Display/Capture Time to Take Reading then screen should notify that readings are not taken and its time to take reading. Notification will be different in manned and unmanned station. In case of manned station message will be displayed on screen. And in case of unmanned station message will be inserted in message table for all supervisor users. Supervisor user is one whose role is defined as "SUPER ". Sample frequency is made available for 100% inspection and sampling technique. Time to take reading message will not get display or recorded if check box of Display/Capture Time to Take Reading is not checked.

Deletion of reading and Sample –

- While deleting the sample it will check for corrective action has been taken or not, if corrective action has been taken then it will display. "Corrective action has been taken. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on Yes the sample is deleted.

- While deleting the sample it will check for trends. If trend raised it will display. "Trends have been raised. Do you want to delete the sample? " If the user clicks on No the sample is not deleted, if the user clicks on Yes the sample is deleted.

In both cases i.e. in case of sample deletion or reading deletion when the reading no is zero for the parameter and the user clicks on F6 the user should not be allowed to delete a reading or a sample.

In case of Single Instrument multiple Parameter –

User selects the sample or reading and selects Delete Reading/Sample system will prompt the message "Are you sure Do you want to Delete reading only for the selected Parameter?"

With Yes or No

If user Press ‘Yes’ then record for selected parameter for selected Reading serial No. will get deleted and charts get refresh with updated Reading Serial No.

If user Press ‘No’ then system will prompt the message "Are you sure Do you want to delete reading for all parameter?" with Yes or No. If user press ‘Yes’ then record for all parameters for selected Reading Serial Number will get deleted and chart get refresh. If sample is completed then the user try to delete the reading then whole sample will get deleted. If sample is not completed then only specific reading will get deleted.

Job is of Single instrument multiple parameter having 3 parameters, Sample size is 3, First two parameter has taken 2 reading i.e. 2/3. Third Parameter has taken 1 reading i.e. 1/3. User tries to delete the reading of 3rd parameter. Message should display ‘Can not delete reading for the selected parameter as parameter is of Single Instrument and then delete operation will get cancelled.

Remarks –

If the online chart displayed is X Chart when the user right clicks on the reading no, it displays three menu options, add remark, view remark, delete reading/sample When the user clicks on add remarks, remarks for reading screen are displayed. User is allowed to enter the remarks and click on Ok, which will launch reading sample screen. If the user clicks on cancel it will still launch reading sample screen. If a remark is present then it will show the remarks for the selected reading else it will show the Reading Sample screen

Corrective Action –

When Sample has trend and user moves the mouse pointer on that sample then it should display the Corrective action as popup similar to Add Remark, view Remarks. If the User clicks on the corrective action menu it should display a separate screen showing the trends and their level and when the user clicks on the Ok button, the corrective action screen will be launched allowing the user to take corrective action. Once the user takes corrective action that samples color becomes blue and it is large and displays the vertical line.

If the color of the sample is blue then it means corrective action has been taken and if the user selects the sample the corrective action screen is displayed with the corrective action that are taken.

On-Line Chart Plotting –

If points are outside control limits then the sample is colored as red. If runs up trend for mean/range, runs down for mean/range, greater than mean/range, less than mean/ range trends are raised then the sample is colored as red.

Angle Parameter-

If parameter is of type Angle then user tries to move the mouse pointer on Sample then reading will display in both format i.e. Angle & decimal.  This is done for X, X-MR, X Bar R and X Bar S Chart.

Histogram will always display in decimal whether parameter UOM is angle or Not.

Print Label as CL in histogram. Value of Centerline will be the Nominal value of that Parameter. Centerline would be red in color and the label would be CL

Trends

Trends are raised when sample size is greater than one and the average of the readings within the sample is out of limits. The last Customized Trend Message along with the date and time is displayed in a log window. You can scroll through this window to view the history of trends raised for the parameter.


The Take Decision Tab (Decision)

Specify the Decision Type – whether Sorting, Special Release, Scrap, Repair or Rework. Before you define a decision type, there must be a related record in the Part-Machines master for the job.

If decision type is Sorting, enter No. Of Units in the Sorting frame.

If decision type is Special Release, enter No. Of Units in the Special Release frame.

 If decision type is Scrap, enter No. Of Units in the Scrap frame. Rate Per Unit is displayed from the Machine master. Value is displayed as No. Of Units * Rate Per Unit.

If decision type is Repair, enter No. Of Units in the Repair frame. Rate Per Unit is displayed from the Machine master. Value is displayed as No. Of Units * Rate Per Unit.

If decision type is Rework, all processes from the Work Order QAP Process table are displayed in the Rework frame. Enter No. Of Units.

Enter Remarks, if any. Click OK to save.

After records are saved, they do not appear under the Pending Decisions tab of Local Monitoring and Global Jobs screen. When the decision taken is Sorting, the record is displayed under the Sorting Analysis tab of Local Monitoring and Global Jobs screen.


The Corrective Action Tab (Decision)

Specify whether the Responsibility for the Corrective Action is assigned to User or Department. Select User/Department from the drop down list which displays related values. Select the actual user who takes the corrective action from the drop down list in the Taken By field. Select Target Date by which corrective action is to be taken. Select Root Cause from the drop down list. Enter the Action taken. Click OK  to save.

Please note:

If the Sorting Analysis tab of Local Monitoring or Global Jobs screen is active,  the Take Decision tab is launched with the Sorting frame disabled. You can enter details for the other four Decision Types. The total Number Of Units in the Special release, Scrap, Repair and Rework frames must not be greater than the Number Of Units displayed in the Sorting frame. The Corrective Action tab is disabled.

At the time of manual recording of readings, in the Local Monitoring screen:

In case of manned configuration, if corrective action is compulsory at level one is checked or corrective action is compulsory at level two is checked or both are checked then you must take both decisions and corrective actions immediately. The Decision screen is launched with both tabs enabled. If you take a decision, but do not enter corrective action details, you are prompted that "Corrective action has not been taken for the decision".


Gauge R & R Data Analysis

Use this option to analyze the results of the study carried out for the gauge i.e. Instrument. You can also view Percentage R&R result using the Average And Range method and ANOVA method.

Completed studies from all the stations are displayed in this screen. Completed studies are those studies for which all trials have been completed using the Gauge R&R Mapping option. If no Gauge R&R study has been closed from any station then the message ‘No studies have been closed’ is displayed.

Select Station No. from the drop down list which displays all stations from which Gauge R & R study has been carried out and completed. Select Instrument Code from the drop down list which displays the  instruments for the selected Station No. for which studies have been closed. Select Part Code from the drop down list which displays the related parts for the selected Station No. and Instrument Code. Select Parameter Code from the drop down list which displays the related parameters for the selected Station No., Instrument Code and Part Code.

The Process Variation or Tolerance value options are visible on the screen only if a value has been entered for these respectively for the selected study while mapping.

If only Tolerance value has been entered for the selected study then on the Data Analysis screen the Total Variation and Tolerance options are visible. If Process Variation has been entered then Total Variation and Process Variation options are visible.

If both the values are entered for the study then all the three options are visible on the screen.

Select the required option from Total Variation, Process Variation, Tolerance or Pp method. Total Variation is selected by default. You may select Process Variation or Tolerance only if values have been specified in the related fields for the selected record in the Gauge R & R Mapping  screen.

Study Date, End Date (i.e. the date when the last trial was taken), calculated values of % R & R (Average and Range Method) and % R & R (ANOVA Method) for the Station No, Instrument Code, Part Code and Parameter Code are displayed in the grid based on selection of Total Variation, Process Variation or Tolerance options.

Click Avg & Range Report to view the Gauge R & R Report (Average And Range Method).

Click ANOVA Report to view the Gauge R & R Report (ANOVA Method).

Click Chart to view the Chart for Gauge R & R.

   Calculate %R&R for average and Range Method and ANOVA method using Pp method.

   To use the Pp option, use the following TV in the GRR analysis [ANOVA and Average & Range Report].

Pp = USL-LSL/6 Sigmap  = USL – LSL / 6s  = USL-LSL/6TV

Then   TV = USL – LSL / 6 Pp

And PV = Square root (TV2 – GRR2)

When using the Pp approach to TV, the calculation for ndc  is

TV2 = PV2 + GRR2

Or PV2 = TV2 - GRR2

Then

ndc = 1.41(PV/GRR) = 1.41 Square root (T V2 – GRR2) / GRR


Gauge R&R Report (Average And Range Method)

The Average & Range method (XBar & R) is a mathematical method which will provide an estimate of both repeatability and reproducibility for a measurement system. Average and range method allows the measurement systems to be decomposed into two separate components, repeatability and reproducibility, but not their interaction.

The ANOVA method can be used to determine this interaction between the gauge and the appraisers.

However both the Average and Range method and ANOVA method will provide information concerning the causes of measurement system or gauge error.

This report displays the results of Gauge R&R Study using the Average and Range method. All readings and calculated results are displayed. The results are shown in terms of the Repeatability percentage, Reproducibility percentage, percentage of Part Variation, percentage R&R and Total Variation percentage.

Repeatability percentage is the Equipment Variation percentage.

Reproducibility percentage is the Appraiser (Operator) Variation percentage.

The calculations of percentage contribution of variations are based on Total Variation, Process Variation or Tolerance value.


Gauge R&R Report (ANOVA Method)

Analysis of Variance (ANOVA) is a statistical technique for analyzing data that tests for a difference between two or more means by comparing the variances "within" groups and variances "between" groups.

The Average & Range method (XBar & R) is a mathematical method which will provide an estimate of both repeatability and reproducibility for a measurement system. Average and range method allows the measurement systems to be decomposed into two separate components, repeatability and reproducibility, but not their interaction.

The ANOVA method can be used to determine this interaction between the gauge and the appraisers.

However both the Average and Range method and ANOVA method will provide information concerning the causes of measurement system or gauge error.

This report displays the results of Gauge R&R Study using the ANOVA method. All readings and calculated results are displayed. The results are shown in terms of the Repeatability percentage, Reproducibility percentage, percentage of Part Variation, percentage Interaction, percentage R&R and Total Variation percentage.

Repeatability percentage is the Equipment Variation percentage.

Reproducibility percentage is the Appraiser (Operator) Variation percentage.

Percentage Interaction is the interaction of part and appraiser percentage.

The calculations of percentage contribution of variations are based on Total Variation, Process Variation or Tolerance value.


Charts (Gauge R&R)

X Bar R Chart

The X Bar R Chart plots the average and range of data collected for each part number by each operator.

Error Chart

The Error Chart is a tool for Error Analysis. The chart is drawn on the basis of reference values defined during mapping of instruments to parts and parameters for Gauge R & R study.

An Error Chart takes measurement data and displays its individual deviations from the accepted reference. It reveals the amount of variation that any parameter of a part has from its reference value. The horizontal axis of the Error Chart represents the error value for different operators for different trials of a part. The vertical axis of the Error Chart represents the range of errors for measurements of the part – parameter.


Stability Mapping

Use this option to study the stability of an instrument over a period of time. This is done by mapping the instrument to a part and its corresponding parameters through different reading modes on a study date. You may view the variance in the stability of the instrument in the form of a chart or a report.

You can see details of the Instrument, Part and Parameter on which the readings will be taken. Reading mode, number of decimal places required for the readings, number of readings taken, date of study and last reading date and time for the instrument are also displayed.

The local machine will display all studies mapped on that machine. Once the study is closed by clicking Close Study, then that study is not displayed on the screen.

Click Add to add a new record. Select Instrument Code from the drop down list displayed from the Instrument master. Study Date displays the current date. Select a date not less than the current date, if required. Select Part Code from the drop down list displayed from the Part master. Select Parameter Code from the drop down list. This list contains only those parameters which have not been mapped to the selected instrument code, study date, part code and local machine.

Select Decimals by clicking the up or down arrows attached to the field. The default value is 0. Specify the Reading Mode – whether Automatic or Manual. It is set to Automatic by default.

Click Save to save the record. You can map only as many parameters as are specified for the interface code of the instrument.

Once a parameter has been mapped for an instrument, the same Reading Mode is set for all subsequent parameters.

Click Modify to make changes. You can modify Decimals and Reading Mode. If you change Reading Mode for a parameter, the same change is made for all other parameters mapped to that instrument code on that study date.

Click Measure if you wish to go to the Stability Measurement screen to record readings. You must map the total number of parameters which are specified for the interface code of the instrument before you can click Measure. Otherwise a message will be displayed and the screen will not be launched.

You can view Reports and Charts if one or more sets of readings have been entered for a study.

Click Report to view a report displaying details of the stability of the instrument over a period of time.

Click Chart to view a graphical image of the details of the stability of the instrument over a period of time. The Chart Selection screen is displayed. Select XbarR or XMR chart.

Click Close Study to close the stability study for an instrument. The data related to this study is then transferred to the Stability Data Analysis screen.

Click Delete to delete a record. You can delete a record for a Local Machine only if trials have not begun for it. For deleting a record, you must specify the Instrument Code, Study Date, Part Code and its corresponding Parameter by selecting them from the respective drop down lists.


Stability Measurement

This screen gives you a facility to capture the readings for an Instrument both Manually and Automatically. You can take simultaneous readings for all the parameters mapped to an instrument. Details of the Channel No., Serial/Parallel Port, and Port No. for the Instrument are also provided.

Reading Mode and Station No. are displayed from the Stability Mapping screen. The current user is displayed as the Operator Code.

For Manual Reading Mode, the Operator Code is used to identify by whom the readings were taken. Channel No. and Port Details (whether Serial Port or Parallel Port, Port No.)  are not defined.

For Automatic Reading Mode, Port settings will be displayed based on the selected and connected instrument. If the instrument is connected to a serial port, then the Serial Port value is displayed as Port No. If the instrument is connected to a parallel port, then the parallel port number and the channel to which instrument is connected will be displayed as Port No. and Channel No. respectively.

A grid is provided for taking readings. The number of columns for readings will be equal to the number of parameters mapped to the instrument. The readings columns display the parameter names as the headings. e.g. If for the Dumore instrument, 3 parameters ID1, ID2, ID3 are mapped  in the Stability Mapping screen, then the Stability Measurement  screen is launched with the provision of three column for the reading values. The reading value column headers have names as ID1, ID2, and ID3 respectively.

There will be only one row for the grid since at one trial only one reading can be taken for the mapped parameters.

Enter multiple lines of remarks on the reading taken in the Remarks textbox. The Start button is enabled only when the reading mode is Automatic.

Click Modify to make changes. You can modify Channel No. and Port No. only if the reading mode is Automatic. If the Interface for the instrument selected in the study has serial port settings, then you can modify only Port No. If the interface for the instrument selected has parallel port settings, then you can modify only Channel No.

Taking Measurements

In Manual mode, you can enter readings directly into the grid for the parameters in the respective columns. You can modify readings only until they are saved.

In Automatic mode, select the row in the grid. Click Start. The readings are displayed in the respective parameter cells when you press the switch on the instrument. They are displayed with appropriate decimals places that are set to each parameter while mapping. Readings displayed in this way cannot be modified.

After the readings are entered or displayed, you can enter Remarks about the readings taken.

Click Cancel to cancel all the readings and remarks displayed and you can take readings afresh.

Click Save to save readings after all readings for all parameters have been taken. You cannot save only a part of the readings. A reading cannot be modified once it is saved.

Click Close to return to Stability Mapping screen. The Last Trial Date, Last Trial Time and Trials Done are updated for the parameter(s) for which the trial was taken.

See Also: Stability Data Analysis


Stability Data Analysis

Use this option to analyze the results of the Stability study carried out for the Instrument. You can analyze the results using Charts and Reports. You can only view the data in this screen without making any changes.

Completed studies from all the stations are displayed in this screen. Completed studies are those studies which have been closed using the Stability Mapping option. If no Stability study has been closed from any station then the message ‘No studies have been closed’ is displayed.

Select Station No. from the drop down list which displays all stations from which the Stability study has been carried out and completed. Select Instrument Code from the drop down list which displays the instruments for the selected Station No. for which studies have been closed. Select Part Code from the drop down list which displays the related parts for the selected Station No. and Instrument Code. Select Parameter Code from the drop down list which displays the related parameters for the selected Station No., Instrument Code and Part Code.

Study Date, End Date (i.e. the date when the last trial was taken) and No. Of Readings for the Station No, Instrument Code, Part Code and Parameter Code are displayed in the grid.

Stabilility Charts

Click Chart to view a graphical image of the details of the stability of the instrument over a period of time. The Chart Selection screen is displayed. Select XbarR or XMR chart.

The XbarR chart plots the average and range of data collected for each sample.

The XMR chart plots the reading and moving range of data collected for each reading.

Stability Report

Click Report to view a report displaying details of the stability of the instrument over a period of time.


Bias Mapping

Use this option to map parts and parameters to the instrument for which Bias study is to be carried out.

Once all readings for all parameters have been completed then that study is not displayed on this screen. The local machine will display all studies mapped on that machine.

Click Add to add a new record. Select Instrument Code from the drop down list displayed from the Instrument master. Study Date displays the current date. Select a date not less than the current date, if required. Select Part Code from the drop down list displayed from the Part master. Select Parameter Code from the drop down list. This list contains only those parameters which have not been mapped to the selected instrument code, study date, part code and local machine.

Enter the Master Value. Specify the Reading Mode – whether Automatic or Manual. Enter Tolerance and Process Variation. At least one of these two fields must be entered.

Select Decimals and No. Of Readings by clicking the up or down arrow attached to the fields. The default value for Decimals is 0 and No. Of Readings has a value between 5 and 30.

Process variation is added to calculate %EV i.e. to determine the repeatability is acceptable.

Click Save to save the record. You can map only as many parameters as are specified for the interface code of the instrument.

Once a parameter has been mapped for an instrument, Reading Mode and No. Of Readings are set for all subsequent parameters.

Click Modify to make changes. You can modify Decimals, Reading Mode, Master Value, No. Of Readings, Tolerance and Process Variation only if readings have not begun for the selected Instrument Code, Part code and Parameter code. If some readings have been taken for the mapped part and parameter then you can modify only Decimals and Reading Mode. If you change Reading Mode or No. Of Readings for a parameter, the same change is made for all other parameters mapped to that instrument code.

Click Measure if you wish to go to the Bias Measurement screen to record readings. You must map the total number of parameters which are specified for the interface code of the instrument before you can click Measure.

After taking all readings which are specified in the No. Of Readings field for all parameters of the selected Study Date, Instrument Code and Part Code, that particular study will get closed. The data related to this study is then transferred to the Bias Data Analysis screen.

Click Delete to delete a record. You can delete a record for a Local Machine only if readings have not begun for it. For deleting a record, you must specify the Instrument Code, Study Date, Part Code and its corresponding Parameter by selecting them from the respective drop down lists.


Bias Measurement

This screen gives you a facility to capture the readings for an Instrument both Manually and Automatically and to calculate the Bias value. You can take simultaneous readings for all the parameters mapped to an instrument. Details of the Channel No., Serial/Parallel Port, and Port No. for the Instrument are also provided.

Reading Mode and Station No. are displayed from the Bias Mapping screen. The current user is displayed as the Operator Code.

For Manual Reading Mode, the Operator Code is used to identify by whom the readings were taken. Channel No. and Port Details (whether Serial Port or Parallel Port, Port No.)  are not defined.

For Automatic Reading Mode, Port settings will be displayed based on the selected and connected instrument. If the instrument is connected to a serial port, then the Serial Port value is displayed as Port No. If the instrument is connected to a parallel port, then the parallel port number and the channel to which instrument is connected will be displayed as Port No. and Channel No. respectively.

A grid is provided for taking readings. The first column displays Reading numbers from 1 to ‘n’, where ‘n’ is the number of readings specified in the Bias Mapping screen. The balance columns of the grid are for readings. The number of columns for readings is equal to the number of parameters mapped to the instrument. The readings columns display the parameter names as the headings. e.g. If for the Dumore instrument, 3 parameters ID1, ID2, ID3 are mapped  in the Bias Mapping screen, then the Bias Measurement  screen is launched with the provision of three column for the reading values. The reading value column headers have names as ID1, ID2, and ID3 respectively.

The Start button is enabled only when the reading mode is Automatic.

Click Modify to make changes. You can modify Channel No. and Port No. only if the reading mode is Automatic. If the instrument selected is connected to a serial port, then you can modify only Port No. If the instrument selected in the study is connected to a parallel port, then you can modify only Channel No.

Taking Measurements

You can select the Reading No. randomly to take readings.

In Manual mode, you can enter readings directly into the grid for the parameters in the respective columns. You can modify readings only until they are saved.

In Automatic mode, select the row in the grid. Click Start. The readings are displayed in the respective parameter cells when you press the switch on the instrument. Readings displayed in this way cannot be modified.

Click Save to save readings. It is not necessary to enter the total number of readings at one time. A reading must be complete before it can be saved i.e. all parameters mapped to the current instrument must have values. A reading cannot be modified once it is saved.

Click Close to return to Bias Mapping screen. The Last Reading Date, Last Reading Time and Readings Taken are updated for the parameters for which the reading was taken.

See Also: Bias Data Analysis


Bias Data Analysis

Use this option to analyze the results of the Bias study carried out for the Instrument. You can only view the data in this screen without making any changes.

Completed studies from all the stations are displayed in this screen. Completed studies are those studies for which all readings have been taken. If no Bias study has been closed from any station then the message ‘No studies have been closed’ is displayed.

Select Station No. from the drop down list which displays all stations from which the Bias study has been carried out and completed. Select Instrument Code from the drop down list which displays the instruments for the selected Station No. for which studies have been closed. Select Part Code from the drop down list which displays the related parts for the selected Station No. and Instrument Code. Select Parameter Code from the drop down list which displays the related parameters for the selected Station No., Instrument Code and Part Code.

Select % Bias Based On whether Tolerance or Process Variation.

Study Date, End Date (i.e. the date when the last reading was taken) and % Bias for the Station No, Instrument Code, Part Code and Parameter Code are displayed in the grid. The calculated value of % Bias is based on the selection of Process Variation or Tolerance options provided on the screen. If the related value for Process Variation or Tolerance has not been entered, a dash character ("—") is displayed in the % Bias column.

Bias Report

Click Report to view a report displaying details of the bias study of the instrument.


Bias Report

This report contains:

Details of the Instrument, Part, Parameter and Station on which the readings have been taken.

The Reading Mode, Reference Value and Number of Readings.

The Tolerance or Process Variation depending on the selection made in the Bias Data Analysis screen.

Readings, Observed Average, Measurement System Bias and % Bias for the instrument.


Linearity Mapping

Use this option to map different part-parameter links to the instrument for which Linearity study is to be carried out. Parts selected should be throughout the operating range of the measurement instrument.

The local machine will display all studies mapped on that machine. Once trials for a study are complete, mapping details will not be displayed in this screen.

Click Add to add a new record. Select Instrument Code from the drop down list displayed from the Instrument master. Study Date displays the current date. Select a date not less than the current date, if required.

Specify the Reading Mode – whether Automatic or Manual. It is set to Automatic by default. Enter Process Variation. This is the standard deviation and is used for calculating Linearity and Percentage Linearity to Process Variation.

Select Decimals and No. Of Trials by clicking the up or down arrow attached to the fields. The default value for Decimals is 0 and No. Of Trials has a value between 5 and 30.

Process variation is added to calculate %EV i.e. to determine the repeatability is acceptable.

You must enter links in the grid. Links are parts selected throughout the operating range of the instrument.  Enter Part in the first column, Parameter for the part in the second column and Master Value for the part and parameter in the third column. You can enter multiple parameters for a part and multiple parts can have the same parameter. The same part-parameter combination can be entered only once.

You can define only as many parameters to an instrument on a study date for a particular part as are specified for the interface code of the instrument.

Click Save to save the record.

Click Modify to make changes. You can modify Decimals, Reading Mode, Master Value, No. Of Trials and Process Variation only if trials have not begun for the selected Instrument. If some readings have been taken for the selected Instrument then you can modify only Decimals and Reading Mode.

Click Measure if you wish to go to the Linearity Measurement screen to record readings. Measurements can be taken for all links of the selected instrument and study date .

After taking all readings which are specified in the No. Of Trials field for the selected Study, that particular study will get closed. The data related to this study is then transferred to the Linearity Data Analysis screen.

Click Delete to delete a record. You can delete a record for a Local Machine only if trials have not begun for it. For deleting a record, you must specify the Instrument Code and Study Date by selecting them from the respective drop down lists.


Linearity Measurement

This screen gives you a facility to capture the readings for an Instrument both Manually and Automatically. You can take simultaneous readings for all the parameters mapped for the Linearity Study.

Reading Mode and Station No. are displayed from the Linearity Mapping screen. The current user is displayed as the Operator Code.

For Manual Reading Mode, the Operator Code is used to identify by whom the readings were taken. Channel No. and Port Details (whether Serial Port or Parallel Port, Port No.)  are not required, hence they are not displayed.

For Automatic Reading Mode, Port settings will be displayed based on the selected and connected instrument. If the instrument is connected to a serial port, then the Serial Port value is displayed as Port No. If the instrument is connected to a parallel port, then the parallel port number and the channel to which instrument is connected will be displayed as Port No. and Channel No. respectively.

A grid is provided for taking readings. The first column displays Trial numbers from 1 to ‘n’, where ‘n’ is the number of trials specified in the Linearity Mapping screen. The balance columns of the grid are for readings. The number of columns for readings is equal to the number of links mapped to the instrument. The readings columns display the "Part Code – Parameter Code" as the headings. e.g. If for the Dumore instrument and Part1, 3 parameters ID1, ID2, ID3 are mapped  in the Linearity Mapping screen, then the Linearity Measurement  screen is launched with the provision of three column for the reading values. The reading value column headers have names as Part1-ID1, Part1-ID2, and Part1-ID3 respectively.

If in the above case, Part2 is also mapped in the mapping screen then there are three more readings columns for Part2 links.

Existing readings will be displayed in the grid, but they cannot be changed.

The Start button is enabled only when the reading mode is Automatic.

Click Modify to make changes. You can modify Channel No. and Port No. only if the reading mode is Automatic. . If the instrument selected is connected to a serial port, then you can modify only Port No. If the instrument selected in the study is connected to a parallel port, then you can modify only Channel No.

Taking Measurements

In Manual mode, you can enter readings directly into the grid for the parameters in the respective columns. You can modify readings only until they are saved.

In Automatic mode, select the row in the grid. Click Start. The readings are displayed in the respective parameter cells when you press the switch on the instrument. Readings displayed in this way cannot be modified.

Click Save to save readings after all readings for a particular trial have been taken. You cannot save only a part of the readings for the trial. A reading cannot be modified once it is saved.

Click Close to return to Linearity Mapping screen. The Last Trial Date, Last Trial Time and Trials Taken are updated.

See Also: Linearity Data Analysis


Linearity Data Analysis

Use this option to analyze the results of the Linearity study carried out for the Instrument. You can only view the data in this screen without making any changes.

Completed studies from all the stations are displayed in this screen. Completed studies are those studies for which all readings have been taken. If no Linearity study has been closed from any station then the message ‘No studies have been closed’ is displayed.

Select Station No. from the drop down list which displays all stations from which the Linearity study has been carried out and completed. Select Instrument Code from the drop down list which displays the instruments for the selected Station No. for which studies have been closed.

Study Date, End Date (i.e. the date when the last trial was taken), % Linearity and Goodness Of Fit (R^2) are displayed in the grid.

Linearity Report

Click Report to view a report displaying details of the linearity study of the instrument.

Linearity Chart

Click Chart to view a graphical image of the details of the linearity study of the instrument. The Linearity Chart plots the Bias and Reference Values for all the Parts.


Linearity Report

This report contains:

Details of the Instrument and Station on which the readings have been taken.

The Reading Mode, the different Part-Parameter Links to the instrument and Number of Trials.

The Reference value, Readings, Part Average, Bias, Range, Linearity, % Linearity, Goodness of Fit (R*R) and Slope of Regression Line for the instrument.


Introduction To MSA

MSA which means Measurement System Analysis is an important part of the Production Process. It is used to ascertain the correctness of the readings taken by the different instruments under different conditions.

If you don't conduct gauge studies, you don't know the capability of your gauges or the people who use them. Every measurement is suspect! You must know the uncertainty of your measurement system when making acceptance decisions and for Statistical Process Control.

Why do we need MSA?

We collect data for various reasons. In all cases, the data is analyzed and decisions are made. The effectiveness of the decisions depends upon the quality of the data. The existence of variation in data is inevitable, and all precautions must be taken to reduce it as much as possible. In a manufacturing process, as well as in a service process, the output is affected by various factors at various levels. Output is then measured according to some pre-established methods, a measurement system which has nothing to do with the process. This measurement process is used to generate numerical values of the subject of interest. Therefore, a measurement is defined as: "The assignment of numerical values to things to represent the relations among them with certain properties."

When data is collected, its values are affected by two independent processes. The first is the manufacturing or service process. The second is the measurement system process. The possibility of variation that can creep into the data from the measurement system can make the data unreliable for decision making purposes. Therefore, steps must be taken to reduce the variations in the measurement system as much as possible. Variation in a set of measurements is caused by people collecting the data, methods used to collect data, the data collection environment, measurement equipment used and the object of interest. The interaction between these components and their effect on the numerical values generated as data are to be evaluated to improve the measurement system. A major portion of the work of managing a measurement system is directed towards monitoring and controlling variation from that system.

If the magnitude of variation from the measurement system is not acceptable, then the system must be modified or replaced.

If we improve the manufacturing or service process without this knowledge, then we are tampering with the

process and wasting valuable resources.

A proactive approach to eliminate such waste can be accomplished through MSA.

Measurement system errors can be classified into five categories - bias, repeatability, reproducibility, stability and linearity.

One of the objectives of a measurement system study is to obtain information relative to the amount and types of measurement variation associated with a measurement system when it interacts with its environment. This information is valuable, since for the average production process, it is far more practical to recognize repeatability and calibration bias and establish reasonable limits for these, than to provide extremely accurate gauges with very high repeatability.

Applications of MSA:

A criterion to accept new measuring equipment.

A comparison of one measuring device against another.

A basis for evaluating a gauge suspected of being deficient.

A comparison for measuring equipment before and after repair.

A required component for calculating process variation, and the acceptability level for a production process.

Estimating percentage variation in the process data due to measuring equipment.

MSA studies are of the following types:

Gauge_Repeatability_&_Reproducibility

Stability_Data_Analysis

Bias_Data_Analysis

Linearity_Data_Analysis


Introduction To Stability
Stability

Stability is the total variation in the measurements obtained with a measurement system on the same master or parts when measuring a single characteristic over an extended time period.

Obtain a sample and establish its reference value(s). If one is not available, select a production part that falls in the mid-range of the production measurements and designate it as the master sample for stability analysis. The known reference value is not required for tracking measurement system stability.

On a periodic basis (hourly, daily, weekly), measure the master sample three to five times. The sample size and frequency should be based on knowledge of the measurement system. Factors could include how often recalibration or repair has been required, how frequently the measurement system is used, and how stressful the operating conditions are. The readings should be taken at different times to represent when the measurement system is actually being used. This is account for warm-up, ambient or other factors that may change during the day.

Plot the data on an XBar R or XMR control chart.

Establish control limits and evaluate for out of control or unstable conditions.

Compute the standard deviation for the measurements and compare it with that of the process to determine if the measurement system reliability is suitable for the application.

Study to find the Stability of the measurement system is divided into three parts - Stability Mapping, Stability Measurement and Stability Data Analysis.


stability_report
Stability Report

This report can be generated in the following ways:

In the Stability Mapping Screen, enter or select Instrument Code, Study Date, Part Code and Parameter Code from the respective drop down lists and click Report. The report will be generated only after readings have been taken.

In the Stability Data Analysis screen, select Station No., Instrument Code, Part Code and Parameter Code from the respective drop down lists. Select the required Study Date and End Date from those displayed in the grid and click Report.

The report contains:

All readings entered through the Stability Measurement screen.

Details of the Instrument, Part, Parameter, Station on which the readings have been taken.

The Reading Mode, Study Date and End Date for the readings.

The Reading Serial No., Date, Time and Remarks.


Introduction To Bias
Bias

Bias is the difference between the observed average of measurements and the reference value or true value of the part.

To determine the measurement system’s BIAS at a specific location in the process range, it is necessary to obtain accurate reference value of a part. This can usually be done with tool room or layout inspection equipment.

Measure one of the sample parts precisely on tool room or layout inspection equipment

Have one appraiser measure the same part a minimum of 5 times, using the gauge being evaluated.

Calculate the average of the readings. The difference between the reference value and the observed average represents the measurement system’s bias

If an index is desired, convert bias to a percentage of process variation  (or tolerance), by multiplying 100 and dividing by the process variation (or tolerance).

Study to find Bias is divided into three parts -  Bias Mapping, Bias Measurement and Bias Data Analysis.


Intoduction To Linearity
Linearity

Linearity is the difference in the bias values through the expected operating range of the gauge.

Linearity can be determined by choosing parts throughout the operating range of the measurement instrument. The bias of each one of those chosen parts is determined by the difference between the reference value and the observed average measurement. The slope of the regression line that best fits the bias average versus reference values multiplied by the process variation (or tolerance) of the parts is an index that can represent the linearity of the gauge. To convert gauge linearity to a percentage of process variation (or tolerance), multiply by 100 and divide by the process variation (or tolerance).

As in the bias study, the reference values of the parts can be determined with tool room or layout inspection equipment. Appraiser measures the parts chosen throughout the operating range and the observed average for each part is determined. The difference between the reference value and the observed average is the bias; this is determined for each part chosen. The linearity graph is plotted between biases and reference values throughout the operating range. If the graph shows that a straight line could represent the plotted points, then a best fit linear regression line between biases and reference values represents the linearity between those two parameters. The goodness of fit (R2) of the linear regression line will determine whether the biases and reference values have a good linear relationship. Linearity and percent linearity of the system are calculated from the slope of the regression line and the process variation (or tolerance) of the parts. If the regression line has a good linear fit, then the magnitude of the linearity and percent linearity can be evaluated to determine whether linearity is acceptable. If the regression line does not have a good linear fit, then it is possible that the bias has a nonlinear relationship. This requires further analysis to judge whether the measurement system’s linearity is acceptable.

Study to find Linearity is divided into three parts - Linearity Mapping, Linearity Measurement and Linearity Data Analysis.


Cloning Details

Cloning facility can be carried out at all levels that are Part, Process, and Parameter level.

If the user selects the Part/Process/Parameter and right clicks, clone menu is displayed to the user. If the user clicks on clone menu option a new screen with the title Select Part/Process/Parameter is displayed to the user. User can select one or more Part/Process/Parameter and click on OK Button. The Part/Process/Parameters that are selected will have the same specification of the Part/Process Parameters that was selected in Standard QAP screen. Cloning will be done only within Part, Process and Parameter.


Trend Summary Report

Trend Summary Report is a pre-formatted report. This report will be launched for Current and closed jobs. For current jobs Local or Global Monitor screen should be active and completed more than five samples for individual parameter. For Closed jobs History selection screen will be used.

Click on Reports→Trend Summary Report will launch Date Selection screen and on OK

Click on Reports→History→ Trend Summary Report will launch History Trend Summary, select data and click on OK

Select the Job from one of the above-mentioned screen and click on Trend Summary report from Report of Main menu.  You will get the Date and Time dialog box.  Select the Date and Time from respective controls.

Click on the OK button to confirm the selection and proceed with the generation of reports. Trend Summary Report provides summary of the selected job during the specified period. It displays the Trend raised and the count for all parameter for selected job. Click on Cancel to leave this dialog without making any modifications or to cancel the operation.


History Card

Gauge Management Flag is true. In Report menu display History card.

When user selects History Card from report menu, display History Card screen.

In History card screen display Instrument Available and Instrument selected List box.

Display four Navigation button for move instrument from Instrument Available to Instrument

selected and vice-a-versa. If user select more than one Instrument and click on Ok

then display the history of the Instrument on different worksheet in Excel.


Part wise summary report

Use this option which displays the summary information of each selected part on different sheet and also all the jobs of that part.

Click on Report -> Part Wise Summary Report menu item. A screen for accepting report Dates will be launched. Specify the required period by entering From Date and To Date.

After selecting date it will display all the parts in list box which has readings for the selected period. Provide the option for Select All. When user clicks on select all then it should check all the Part no from list box. When users uncheck the Select All, that time it will uncheck all parts from the list box. User selects 3 parts and click on OK then it should display the information of each part on different sheet.


GRR Result

Select Configuration|GRR Result from the Main Menu to display the GRR Result screen. Use this option to configure GRR Result based on Min & Max Percentage.

This form has only Modify mode option. On Modify operation, user can modify the default data as per their requirement.

User has to enter the data in such a way that Max Percentage should be greater than Min Percentage and also Min Percentage of current should be greater than or equal to earlier Min/max Percentage.


Zone

Use this option to define Zone, Zone Description, Zone Sequence No, and Tray in Zone, which will use for how much time tray, is present in specified zone.

Select Configuration| Zone from the Main Menu to display the Zone master.

When g_HeatTreatment flag is true, in Configuration menu Zone sub menu will get visible.

When no data exist then system will enable Add button and disable Modify, Delete, navigation toolbar button.When data exist then system will enable Add, Modify, and Delete and navigation toolbar button.

When user clicks on Add button then system will set then focus on Zone Code. Disable Add, Modify, Delete button and enable Save, Cancel button. When user has entered code then before move to next system will check for duplication and same thing will check for Sequence No.


Parameter Category

Use this option to define different parameter for a Parameter Category  which has LSL and USL. This will be used for plotting chart of tray.

Select Configuration| Parameter Category from the Main Menu to display the Parameter Category master.

When g_HeatTreatment flag is true, in Configuration menu Parameter Category sub menu will get visible.

When no data exists, system will be enabled only Add button and disabled Modify, Delete, Navigation toolbar button. When data exists, system will be enabled Add, Modify, Delete and Navigation toolbar button.

When user clicks on Add button then system will set the focus on Parameter Category and will be disabled Add, Modify, delete button & enabled Save, Cancel button. When user has entered Parameter category then before move to next, system will check for duplication.


Zone Parameter

Use this option to configure Zone, Parameters and its Captured Reading Time, which will use while plotting a chart.

Select Configuration| Zone Parameter from the Main Menu to display the Zone Parameter master.

When g_HeatTreatment flag is true, then in Configuration menu Zone Parameter sub menu will get visible.

When no data exist then system will show only Zone in a tree on left hand side and on right hand side display zone details like Description, Tray In Zone.

When data exist then system will display 1st Zone of 1st parameter details in a grid. Grid will show all entered Captured Reading Time. Structure of tree is as below.

Zone (Root Node)

    Zone A

Para A

Para B

     	Para C

     Zone B

Para D

Para E

Para F

When user has selected Zone (like Zone A, Zone B) then only Add button will get enabled. When User clicks on Add button, save and Cancel button will get enabled and Add button will get disabled and then system will populate all parameter in a combo box, which was not assigned to zone. When user selects parameter or user can manually enter the parameter then system will display parameter description in respective textbox. Just below parameter description system will provide the grid for entering tray captured reading time. At a time user can enter one time in a grid.

When user has selected Parameter (like Para A, Para B) then Add, Modify, Delete button will get enabled. When user clicks on Add/Modify button then Save, Cancel button will get enabled and add button, parameter combo box will get disabled. In case of Add button, system will set the focus on a new row of a grid. In case of Modify button, system will set the focus on selected row for modification.

While saving the record, system will do the validation for blank or zero, Same Captured Reading Time, Increment order for captured time etc for the zone. When user clicks on Delete button, system will delete the selected parameter and when user press ‘Delete’ button from keyboard of the selected row in the grid then selected Captured Reading Time for a zone-parameter will get deleted. If time is entered by the user which was already assigned for different parameter then system will display message ‘Same Captured Reading Time has defined in parameter PARA’.


Tray Time Entry

Use this option to configure Tray in Date, Time and Tray Number, which will use while plotting a chart.

Select Configuration| Tray Time Entry from the Main Menu to display the Tray Time Entry master.

When g_HeatTreatment flag is True, then in Configuration menu Tray Time Entry sub menu will get visible.

When no data exists then system will show blank combo box & textbox.

When data exist, Date, Time will display in combo box and text box will be use for displaying Tray Number.

In case of Add Mode, system will display date, time in Date Picker control for selection of date and time. On selection of date, system will increment the tray no for a date and it will display in Tray Number textbox.

 In case of Modify Mode, system will visible Date Picker control and set the focus on Time. User can modify time and tray number.

While saving a record a system will check duplication of record for date, time and duplication of tray no for a date. System will check blank or zero value for Tray No.

In case of Delete Mode, when user set the focus on date and try to delete the record then system will delete the record for selected date & Time.


Run Charts

When you need to display the simplest possible display of trends within observation points over a specified period of time. They are used to monitor a process to see whether or not a long-range average is changing. The Run chart is used to focus attention on truly vital changes in the process.


Histogram

When you need to discover and display the distribution of data by bar graphing the number of units in each category, histograms are extremely useful.


Control Chart

A control chart is simply a run chart with statistically determined upper and possibly lower lines drawn on wither side of the process average.  These limits are calculated by running a process untouched.


Process Capability

When you need to determine whether the process, given its natural variation is capable of meetings the required specifications.

Capability indices let you place the distribution of the process in relation with the specification limits.


X bar

The arithmetic of mean of readings taken from a sample.


X double bar

This is mean of means and it is called as sample mean.


Range

This is the entire span over which readings are taken.


Attributive parameter

This is a parameter for which discrete readings can not be taken. The readings taken are of the type  "acceptable" and "not acceptable".


Variable Parameter

This is a parameter where you may associate a numerical value as its reading.


Quality Assurance Plan

An initiative towards implementation of a quality system involves details of planning at the three levels, viz., part, process, and parameters. The control limits, sample size and the number of samples to be taken defined in the quality assurance plan.


USL - Upper specification limit

An upper specification limit, also known as USL, is a value below which performance of a product or process is acceptable.

The value of a parameter may not exceed this limit in the manufacturing process as part of quality requirement.


LSL - Upper specification limit

A lower specification limit is a value above which performance of a product or process is acceptable.
The value of a parameter may not go below this limit in the manufacturing process as part of quality requirement.


Cp

Cp is a simple process capability index that relates the allowable spread of the specification limits to the measure of the actual or natural variation of the process. It is expressed mathematically as:

Where is the average of the subgroup ranges and d2 is a tabled value based on the subgroup sample size.

Cp provides an indication of how capable the process is of meeting the specifications expected by the customer.

It is a simple capability index that relates the allowable spread of the specification limits (USL and LSL) to the measure of the actual, or natural, variation of the process.

The process can be analyzed based on the value calculated for Cp as given below.

1.33 <= Cp	- Satisfiable enough

 In this case, the process variation is less than the specification and the readings will be lying more close to X double bar. The normality curve plotted for this will look sharp and narrow in width.

1.00 <= Cp < 1.33	- Adequate

In this case, the process is just meeting the specification minimum of 0.3% defectives will be made, more if the process is not centered.

Cp < 1.00	-Inadequate.

In this case, the process variation exceeds the specification and more defectives are made. The normality curve plotted for this will look fat in width.


Cpk

This is capability index for a stable process. Cpk is defined as min {Cpu, Cpl}

Cpk looks at how well the X double bar is centered to the target value.

When the process is running on nominal, then Cpk = Cp.

For process to be capable, the values of both Cp and Cpk have to be > 1.


Job

A combination of part, process, work-order, batch and machine is treated as a job in ProQMS. The quality data is collected for a job.


Work Order

A document prepared by production to initiate production activity.


Work Order QAP

Quality Assurance Plan modified suitably for a work order.


Local Monitoring

Monitoring job initiated on a current computer.


Global Monitoring

Monitoring jobs initiated on other computers in a network environment.


Decision

Action to be taken about the non-conforming samples.


Sorting

A type of decision wherein selected pieces may sent for further decision.


Scrap

A type of decision where in a piece may be discarded.


Special release

A decision considering the non-conforming sample as "acceptable" as special case and releasing it.


Rework

Sending the non-conforming pieces for redoing some process.


Homogenization

In case of mean of the sample is out of control limits then this value may affect the statistical calculation that reflects the behavior of the process. In such case the reading(s) the mean out of control limits may be assigned a cause and marked as deleted.


Normality Curve

 A curve that is plotted on Histogram that indicates the distribution of the captured data.


Corrective Action

Action of taking some right step towards correcting the cause of non-conformity.


History Data

The data collected for a job, after closure of a job or work order, is referred to as history data.


Interface code

Code of the device instrument to which a particular instrument is attached.


MAN

Manual mode of entering reading through keyboard. No interface is connected to the instrument.


PMDI-1

Parallel Mitutoyo type digital interface to which a single Mitutoyo type digimatic instrument can be connected.


PMDI-4

Parallel Mitutoyo type digital interface to which up to 4 Mitutoyo type digimatic instruments can be connected.


PMDI-4

Parallel Mitutoyo type digital interface to which up to 8 Mitutoyo type digimatic instruments can be connected.


WB

Interface for weighing balance.


BTP

Interface for connecting Baker Mercer probes.


Data Source Name

The logical name used by ODBC to refer to the drive and other information required to access data.


Server Name

 Name of server where database is.


Specialix / Moxa

Asynchronous adapter for attaching serial devices


Corrective Action

Action to be taken for resolving nonconformity.


PROBE

 Each gauge attached to a fixture is individually called as a probe.


Probe No.

Serial number of a probe connected to a fixture.


Non Conformity

Sample which does not conform to specification limits or control limits.


Optional

Specifies the parameter category


Critical

Specifies the parameter category


Sample Size

Number of units to be measured for a sample


Sample Frequency

Frequency for collecting sample data.


100% Inspection

All events or measurements used to analyze the performance of a process


Sampling

One or more events or measurements used to analyze the performance of a process.


Subgroup Size

Number of units for a subgroup


Continuous reading

Readings form connected gauge will be saved to database continuously without confirmation.


Interactive reading

Readings form connected gauge will be saved to database on confirmation.


Specification Limits

The engineering requirement for judging acceptability of a particular characteristic. A specification is never to be confused with a control limit. Ideally specification ties directly to or is compatible with the customer’s requirements or expectations. User can modify LSL, USL, Nominal value, Sample size and Frequency of more than one parameter through this screen.

When the user click on Specs Limit button then Change Specification Limit screen will get display. Instrument address column get visible only in the grid for process-parameter having interface code as ‘ESYA’. User can see all parameters instrument address through this screen.

Cpk for Sample No’s should not be blank but can be zero.


Control Limits

Control limits reflect the expected variation in the data


Nominal value

It refers to the value that you estimate in a design process that approximate your real target value


Parameter

Characteristics of a part, that can be measured or counted for recording and analysis.


P Chart

For monitoring the percent of samples having the condition, relative to either a fixed or varying sample size, when each sample can either have this condition, or not have this condition.


nP Chart

For monitoring the number of times a condition occurs, relative to a constant sample size, when each sample can either have this condition, or not have this condition


U Chart

For monitoring the percent of samples having the condition, relative to either a fixed or varying sample size, when each sample can have more than one instance of the condition


C Chart

For monitoring the number of times a condition occurs, relative to a constant sample size, when each sample can have more than one instance of the condition


X Bar R Chart

The X-bar chart monitors the process location over time, based on the average of a series of observations, called a subgroup. The Range chart monitors the variation between observations in the subgroup over time.


X Bar S Chart

The X-bar chart monitors the process location over time, based on the average of a series of observations, called a subgroup. The Sigma chart monitors the variation between observations in the subgroup over time


Histogram

A bar graph of a frequency distribution in which the widths of the bars are proportional to the classes into which the variable has been divided and the heights of the bars are proportional to the class frequencies.

A histogram is a basic graphing tool that displays the relative frequency or occurrence of continuous data values showing which values occur most and least frequently. A histogram illustrates the shape, centering, and spread of data distribution and indicates whether there are any outliers.


X MR Chart

The X chart monitors the process over time , based on the individual readings . The MR chart monitors variation between individual readings.


X Chart

The X chart monitors the process over time, based on the individual readings.


Pareto Chart

A simple tool for problem solving that involves ranking all potential problem areas or sources of variation according to their contribution to cost or to total variation. Typically, a few causes account for most of the cost (or variation), so problem –solving efforts are best prioritized to concentrate on the "vital few" causes, temporarily ignoring the "trivial many."


Equipment Variation

EV = R Double Bar * K1


Appraiser variation

AV =

Where n = no of parts, r = no of trials.


Repeatability & Reproducibility

R&R=


Part -To - Part variation

PV =  Rp * K3


Total Variation

TV =     (R&R2 + PV2)


Repeatability

Repeatability is the variation in measurements obtained when one person takes multiple measurements using the same instrument and techniques on the same parts or items.

Repeatability refers to variation in a series of measurements that have been taken with one gauge measuring one characteristic of the same item by the same person.


Reproducibility

Reproducibility is the variation in average measurements obtained when two or more people measure the same parts or items using the same measuring technique.

Reproducibility refers to variation in a series of measurements that have been taken with one gage measuring one characteristic of the same item by different people


Corrective Action

Action to eliminate the cause of a detected nonconformity. There can be more than one nonconformity. Corrective action is taken to prevent recurrence. Correction relates to containment whereas corrective action relates to the root cause.


Pending Decision

Detected nonconformity needs to be resolved.


Model

Product


Operation

Process, the combination of people, equipment, materials, methods, and environment that produce output – a given product or service. A Process can involve any aspect of our business. A key tool for managing process is statistical process control.


Gauge R&R
Gauge R&R(old)

Gauge R&R, which stands for gage repeatability and reproducibility, is a statistical tool that measures the amount of variation in the measurement system arising from the measurement device and the people taking the measurement.
"Gauge R&R is intended to be a study to measure the measurement error in measurement systems."


Root Cause

A factor that caused a non-conformance and should be permanently eliminated through process improvement


Sample

A portion or subset of units taken from the population whose characteristics that would be used for analysis are considered to be identical with a notion that any unit can represent the population.


Subgroup

A distinct group within a group; a subdivision or subset of a group


Range

Range is an estimate of spread in a set of data points; the difference between the highest and lowest values in the data set.


Pre-control Chart

Chart for online reading analysis.


Internal Rework

Job created for rectification of non-conformity. :


Advantech card

Advantech  / PCL-818L card is high performance multi-function data acquisition card for IBM PC/XT/AT or compatible computers.


Control Limits For X bar R chart

UCLr =

LCLr =

LCLx =

UCLx=


Control Limits for X bar S chart

LCLs =

UCLs =

LCLx =

UCLx =

S = SD (n-1) for each sample


Control Limits for X bar MR chart

UCLmr =

LCLmr =

UCLx =

LCLx =


Process Performance

Pp

This is the performance index which is defined as the tolerance width divided by the process performance,irrespective of process centering.

Ppk

This is the performance index, which accounts for process centering and is defined as the minimum of (Ppl, Ppu)


Setting Value

Master value


Calibration Value

While checking Master value, deviation between measured value and Master value is set with the help of some value, that is calibration value


Dynamic Parameter

Parameter is changing nature. Parameter is measured through Min, Max, Avg., TIR.


Gain Factor

Adjustment for offset between upper and lower master.


Reground

 Repair to regain its original form once the tool is worn out.


Mastering

 Measurement of Master piece and consider it as standard for calibration of particular Gauge.


Work Station

 Particular machine on shop floor for production.


Tolerance

 Allowed deviation for specification of the parameter i.e.,USL-LSL


Probe Range

 Specify value as a range for the probe


Master Value

Measurement of Master piece to set it as standard.


Overview of Pro QMS

Quality Management with Pro-QMS

Pro-QMS is an extremely powerful tool for implementing the Quality Assurance Plans in the manufacturing industry.

Pro-QMS helps in the implementation of quality plans during the manufacturing process as opposed to traditional methods where quality testing is done after completion of the process.  The former ensures that failures can be detected at the respective stages of the process, and that monitoring of quality at each stage of the entire manufacturing process contributes to the reduction of the cost at early stages.

The following ISO 9001:2008 clauses form the backbone for Pro-QMS

Control of production and service provision (7.5.1)

Validation of processes for production and service provision (7.5.2)

Monitoring and measurement of product (8.2.4)

Control of nonconforming product (8.3)

Corrective action (8.5.2)

Preventive Action (8.5.3)

Analysis of data (8.4)

This system is designed for use in production environment. This system gives indications to the end users regarding the behavior of process. The user has to take necessary action based on the observations of behavior of process. This system does  not control any process.

PLEASE NOTE: The modules available on your machine will be as per Purchase and Installation by you. However, you may view information of all modules within the system using the Online Help System.

The conceptual structure of Pro QMS is built around the following concepts

Making a Database Connection

Company Settings

Configuration

Quality_Assurance_Plan

Work_Order

Work_Order_QAP

Batch_Maintenance

Job

Monitoring

Data Acquisition

Analysis and Improvement

Non-conformity Management

Multi -Gauge Recording and Analysis of Quality Data

Measurement_System_Analysis

Tool Life monitoring


Making a Database Connection

You may connect to any database, remote or local for storing the process quality data. (See Database)


Company Settings

You can also change the settings that are the global settings throughout your project. The company option is used to provide various settings, which are simulated in the environment. (See Company settings)


Configuration

Setting up all information regarding the parts to be manufactured, process for the manufacturing parts, and machines for processing, instruments and interfaces. (See Defining masters).


The Quality Assurance Plan (QAP)

A standard QAP stands for Standard Quality Assurance Plan, which basically means a quality plan to achieve the quality standards that are defined and followed during the manufacturing process for the part. It will be for a part of a process, the parameters to be considered for quality data recording. These parameters may be of two types Variable and Attributive. (see Quality assurance Plan.)


Work Order

Once the QAP for a part is created, it is followed by creation of a Work Order. A Work Order is a internal production order document prepared for shop/production floor having details of what is to be produced, and how much is to be produced and when to be produced.(See Work Order.)


Work Order QAP

QAP for specific work order is generated through the system on creation of WorkOrder. You may change WorkOrder QAP for specific requirements.(See Work Order QAP)


Batch Maintenance

Target quantity of a WorkOrder may be produced in batches. (see Batch Maintenance)


Job

The job will be created for that particular part, for a specific process, for a work order and for a batch and on a Specific machine. The quality data is collected for a job.(see Job creation).


Monitoring

The monitoring process in Pro-QMS begins after the job has been created. The monitoring may be done globally as well as locally. Local monitoring is done at the place where the job is created. Global monitoring permits multi-location monitoring.(See Local Monitoring , Global monitoring)


Data acquisition in PROQMS

The acquisition of the process data may be done using the following input devices:

Keyboard

Electronic probes

Digital instruments

RS 232/RS 485

The software acquires quality parameter data and checks if it is in the specified limits of tolerance. The process behavior may be observed with respect to the limits of tolerance.

ProQMS uses common yet elaborate statistical techniques that help in analyzing the process data and alarm if the process is deviating from the "normal" behavior. It is expected from the user to take the decisions when the deviation is detected.

Collecting Data for Variable type parameter

Collecting Data for Attributive type parameter

Collecting Data for Pre-Control Chart

Collecting Data Using Fixtures


Analysis and Improvement

Control Charts effectively direct attention towards special causes of variation. Process improvement using control chart is an iterative procedure, repeating the fundamental phases of collection, control and analysis.

The trends raised are displayed on the charts, which gives facility to study and analyze the measurement process.

(See Trend Analysis)


Non-conformity Management

If the readings are out of limits then it is an indication that the parts being produced are faulty. This is a point that calls for decision on the sample such as rework, special release, scrap or sorting.  These decisions are used later for calculating the cost of the quality and in the disposal of non-conformity

Action to eliminate the cause of a detected nonconformity. There can be more than one nonconformity. Corrective action is taken to prevent recurrence. Correction relates to containment whereas corrective action relates to the root cause.

(See Decision

Corrective Actions,

Corrective Actions Completed)


Multi -gauge Recording and analysis of quality data

Facility provided to record the readings for various parameters of a part in a single go using fixtures or otherwise. This helps the user save his time and energy in taking individual readings one at a time.

(See  fixtures

Fixture Mapping

Fixture monitoring)


Gauge Repeatability and Reproducibility
Gauge Repeatability and Reproducibility(old)

Measurement systems are essential to the quality of a manufacturing process. The measurement process itself is subject to variation, and excessive variation in the measurement instruments, referred to as gauges, can mask critical variation in the manufacturing process.

One type of measurement variation is caused by conditions inherent in the gauges. This variation, known as

Repeatability: Occurs when one person measures the same characteristic several times with the same gauge.

Reproducibility: Occurs when different individuals measure the same characteristics with the same gauge.

Other sources of measurement variation include part-to-part variation and lack of accuracy, stability, and linearity

Gauge R&R gives facility to obtain and study information on amount and type of variations related to the system and its interaction with the environment i.e. to record and calculate the Gauge R&R.

(See Part - Parameter Mapping)


Tool life monitoring

Feature that enables Pro QMS users to define and monitor several aspects of the tools used in the manufacturing processes. (see Tool master)


Reports in PROQMS

SPC Reports

History Reports

Tool Life Monitoring Reports


SPC Reports

Charts Displays charts for a job when Local Monitor, Fixture Monitor or Global Monitor screen is active.

Tray Tracking Chart

Displays the information for Tray Tracking for Variation of Parameter Category Screen.

History Calibration Displays information of Instrument No, Calibration date, Calibration due date, Calibrated In house /Company, Remarks, Step code, Description, LSL, USL, Wear Value.

Gauge Calibration Due

Displays gauge calibration due during report, for instruments along with the calibration date, location and who is responsible for the same

Gauge Calibration Overdue

Displays gauge calibration due during report, for instruments along with the calibration due date, location and who is responsible for the same

Machine wise analysis

Displays machine-wise analysis report, which gives details about part, process and all work orders, control limits, Cp, Cpk, Pp & Ppk.

Quality Assurance Plan Summary

Displays report on the summarized Quality Assurance Plan

Quality_Assurance_Plan_Detail

Displays report for the detailed information about quality assurance plan for the selected part(s).

Audit_Trail_For_Homogenized_Samples

Displays report for the samples, which have been homogenized.

Cost of Internal Rejection

Displays a report on the parts rejected during internal quality testing.

Process Capability Study Report

Displays Process Capability details for the selected Jobs.

Process Capability Study Report - Run Chart

Displays Process Capability-Run Chart details for the selected Jobs.

Process Capability Study Report - Histogram

Displays Process Capability-Histogram details for the selected Jobs.

Summary_Report

Displays summary report, of the selected job during the specified period.

All Parameter Readings Report

Display report for all details related to a job.

All Parameter Reading Report [Different Job - One Part]All_Parameter_Reading_Report_for_more_than_one_job All_Parameter_Reading_Report_for_more_than_one_job

Displays the record of multiple jobs with all parameter of different job for one part at a glance.

All Parameter reading report (Station-wise)

Displays information of all jobs that come under selected period for selected station no.

Resend Trend Email

Displays trend for selected date, shift, machine & convert this into .pdf file & then mail will go with currently created pdf file as a attachment, predefined subject, body message and predefined mail id which is based on shift & mail id

Part-wise Daily CpCpk / PpPpk ReportPartwise_Daily_Cp_Cpk_or_Pp_Ppk_Report Parameters_Cp_Cpk_report

Displays the Cp cpk or Pp Ppk details for all the selected parameters defined in all the Job or work orders created between the specified period.

Parameter Cp/Cpk or Pp/Ppk Summary ReportParameters_Cp_Cpk_report Parameters_Cp_Cpk_report

Displays the summary of all readings and Cp Cpk or Pp Ppk details for the selected parameter defined in all the Job or work orders created between the specified period.

Part Wise Summary Report

Displays the summary information of each selected part on different sheet and also all the jobs of that part.

Export Data of Component Number Report

Displays the process wise parameter values for the selected component number.

Date-Wise Export Data of Component Number Report

Displays the date wise component number with parameter values for the selected period, part number and process.

Trend Summary Report

Displays the Trends raised and the count for all parameter for selected job.

Trend V/S Rejection Report

Displays the reading of trends of the variable parameter of the selected job.

Corrective_Action_Trend_Report

Displays report for trends raised

Remark Report

Displays the event remarks that have been already entered for samples and readings of selected job and all variable parameters associated with that job.

Balance Tool Life

Displays the information about the tools that are being used for Production for a Model Code and Machine No.

Model wise Report

Displays the detailed information about the tools, its parameters, operating values and life of the tool for the selected Model(s).

Operation Wise Report

Displays the detailed information about the tools and life of the tool for the selected Machine(s).

Production Report

Displays the details about production of a model for a machine and shift for a specified period.

Tool Parameter ChangeTool_Parameter_Change_Report

Displays the idea about the life of a tool for different values of the parameter.

Tool changeTool_Change_Report

Displays  the idea about when the tool was changed and the reason for the same.


History Reports

History Charts

Displays history charts for closed jobs.

Process_Capability_Study_Report

Displays Process Capability details for the selected Jobs.

Process_Capability_Study_Reports_Run_ChartProcess_Capability_Study_Reports_Run_Chart History_Charts

Displays Process Capability-Run Chart details for the selected Jobs.

Process Capability Study Report - Histogram

Displays Process Capability-Histogram details for the selected Jobs

History Summary Report

Displays history summary report for closed jobs.

History Readings Report

Displays history readings for closed jobs.

All Parameter Reading Report (Different Jobs - One Part)All_Parameter_Reading_Report_for_more_than_one_job All_Parameter_Reading_Report_for_more_than_one_job

Displays the record of multiple jobs with all parameter of different job for one part at a glance.

History Export To ExcelExport_To_Excel Export_To_Excel

Export readings for jobs to Excel for Data Analysis based on the Excel Sheets Where jobs have more than one parameter, each parameter is displayed on a separate sheet.

QS-9000 Report

Displays the information for current and closed jobs.

Trend Summary Report

Displays the Trends raised and the count for all parameter for selected job.

Remarks Report

Displays the event remarks that have been already entered for samples and readings of selected job and all variable parameters associated with that job.


Tool Life Monitoring Reports

Balance_Tool_Life

Displays report, for the balance life of a tool

Model_Wise_Report

Displays report, for the detailed information about the tools, its parameters, for the selected Model(s).

Operation Wise Report Displays report, for the detailed information about the tools and life of the tool for the selected Machine(s).

Production Report

Displays details about production of a model, for a machine and shift.

Tool_Parameter_Change_Report

Displays report, for the life of a tool, for different values of the parameter.

Tool_Change_Report

Details of the tool changed and the reason for the tool change


Local Machine

Use this option to define Local Machines.

Click Add to add a new entry. Enter the following details:

Station Name – The name of the Station.

Ack Parallel Port – The  Acknowledgement Port.

Manned – Whether Manned or not. By default this is set toYes.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record.


Trend Messages

Use this option to map Standard Messages with Customized Messages for the Trends raised. These Customized Messages are displayed when trends are raised in the Measurement screen.

All messages from the Trends table are displayed on screen. Initially the Customized Message is displayed from the Standard Message and Root Cause is blank. Select Root Cause from the drop down list which is displayed from the Root Cause Master.

Click Save to save changes to Customized Messages and Root Causes. Standard Messages cannot be modified.


Search Screen For Charts
Search Engine For Charts

Use the Search Engine For Chart screen to enter selection criteria for which the charts are required.

Enter the Date and Time range required for the Charts. By default, the Current Date and Current Time are displayed in the From and To fields respectively. From Date must not be greater than To Date.

If this screen is launched when either Local Monitoring or Global Jobs screen is active, the drop down lists for Machine No., Part Code and Process Code display values from the respective screens for the job selected in that screen.

If this screen is launched when the Main Application screen is active, the drop down list for Machine No. displays all machines for which jobs have been created within the specified range of dates and time. When you select the Machine No., the drop down list for Part Code contains all parts defined for the selected machine, for various jobs created within the specified range of dates and time. When you select the Part Code, the drop down list for Process Code contains all processes defined for the selected part and the selected machine, for various jobs within the specified range of dates and time.

Select Machine No., Part Code and Process Code from the respective drop down lists.

If no job has been created fulfilling the entered criteria, you cannot view any charts. If only one job exists, click OK to view related charts.

If more than one job exists, the Job Selections screen is displayed.

Select Job. No.  Click OK to confirm the selection and proceed with the generation of charts. You can view all the charts, which are selected in the Work Order QAP. For variable parameters, the charts available are Histogram, X Bar R, X Bar S, X-MR, X, Pre-control & Pareto charts. For attributive parameters, the charts available are P, nP, C & U charts. Click Cancel to leave this screen without making any modifications or to cancel the operation.


Job Creation

While creating the job in job creation and job details mapped sequence needs to be taken care of. The Job creation screen provides the facility when Bilcare Singapore is true. If the parameter has an instrument type PCS then PCS instrument should get attached and if the parameter has instrument type SCADA then default SCADA instrument.  If the parameter has instrument type lamination then Lamination instrument should get attached.

In add mode station no combo will display the local host name in the combo by default and will also display a check box next to the station no combo if the logged in user has a role as "INST". If the user checks the checkbox then the screen for "Computers Connected To Network" will be displayed which displays all the computer names on the default station. If the user selects a computer and clicks on Ok button of the screen the screen for "Computers Connected To Network" that computer name should be displayed in the station no combo. If the user clicks on cancel the screen for "Computers Connected To Network" is closed.

In Job creation screen a checkbox is displayed for Single Instrument for multiple parameter. If user clicks this check box then the functionality one instrument for different/multiple parameters is made available to the user i.e. when the user selects the instrument code for a parameter, then it should be the same for the remaining parameters also for that instrument Type. If   there is a job, which has 5 parameters, out of which 4 parameters have the same instrument type and 1 parameter has a different instrument type, so when the user has selected the instrument for the first parameter then it should display same instrument for the remaining 3 parameters and the user should be allowed to select the instrument for the 5th parameter manually. If user does not select the check box of Single instrument for multiple parameters then user should select the instrument for individual parameter in job creation.

Formula field in the StdQAp should use the parameters if required, which are defined under the selected Part and the Process. User should not define – in the parameter code when that parameter is used in the Formula field.

Interface code for selected instrument type is ‘ESYA’ then Instrument address will get visible. When user selects the instrument is of type ‘ESYA’ then system should attach same instrument for all parameters. While creating a job, Instrument address value will come from QAP for respective Part-process-parameter.

If Windows user is True from Configuration file then Job will get created with Station No which is equal to Station No (PC Name) plus Windows User otherwise Job will get created with Station No (PC Name).

Use this screen for the following:

To create a Job and Work Order simultaneously.

To modify the QAP details for a parameter of a job provided no reading has been taken.

To delete a Work Order, a Job or a Parameter of a job provided no readings have been taken.


Export To Excel

You can export readings for various jobs to Excel. Use this facility for Data Analysis based on the Excel Sheets.

Where jobs have more than one parameter, each parameter is displayed on a separate sheet. Both Variable and Attributive parameter details can be exported.

The data displayed in Excel is all the data related to the job along with all calculated data.

For Variable parameters, the following details are displayed:

From Date, To Date, From Time, To Time, Work Order Number and Date, Part, Process, Parameter, Machine Number, UsL, LsL, UcLx, LcLx, UcLr, LcLr, Nominal Value, Sample Size, Cp, Cpk, Pp, Ppk, S Sqrt, S Rbar/d2, X Double bar, R bar, Number Of Readings, Sample Number, Reading Serial Number, Reading Date, Reading Time, Readings.

For Attributive  parameters, the following details are displayed:

From Date, To Date, From Time, To Time, Work Order Number and Date, Part, Process, Parameter, Machine Number, UcL, LcL, Number Of Readings, Subgroup Size, PBar, UBar, NpBar, Cbar, Reading Serial Number, Reading Time, Readings.

For jobs which have not been closed, select a job from the Local Monitoring or Global Monitoring screen. Click File|Export to Excel from the Main Menu. The Export to Excel screen is displayed.

You may enter Date and Time ranges. If multiple jobs exist, the Job Selections screen is displayed.

Select a job and click OK to launch the readings worksheet in Excel.

For jobs which have been closed, click Reports-History|Export to Excel from the Reports Menu.  The History Summary Report screen is displayed.

Enter the required selection criteria. If multiple jobs exist, the Job Selections screen is displayed.

Select a job and click OK to launch the readings worksheet in Excel.

If you wish to save the worksheet, you must manually save it using the File|Save option in Excel.


Job+WO Creation
Creation Of Job And Work Order

To create a new job, click Add.  The Parameter tab is active.

After clicking Add toolbar button or menu item, Job No. combo will be disabled. Job No. will display current system date and current system time in format dd-mmm-yyyy hh:mm:ss AM/PM. Job No. is also editable and user has facility to enter Job No. of his choice

If duplicate Lot No./Job No. is found system gives message "Job Already Exists"

Select Machine No.  from the drop down list which displays all machines from the Machine master. Select Part Code from the drop down list which displays all Parts defined in the Standard QAP screen. You cannot proceed if no parts have been defined. Select  Process Code which displays all processes defined in the Standard QAP screen for the selected Part Code. You cannot proceed if no processes have been defined.

All Parameters defined for the selected Part Code and Process Code in the Standard QAP screen are displayed. You cannot proceed if no parameters have been defined. Click on the Instrument Code field to display instruments from the Instrument master. Every parameter has an instrument type defined for it. Only instruments of this type are displayed. Select Instrument Code.

Click Save to save the record after all details have been entered. Job. No. and Work Order No. are generated. The QAP for the Work Order is inherited from the Standard QAP. In Add mode, you cannot navigate to the other tabs. The other tabs are Detail, Sampling, Data Access, Limits and Charts.


QAP Modification
Modification Of QAP Details For A Parameter

To modify details for a parameter, click Modify.  Select  Job No.  from the drop down list which displays all existing jobs. Select  Machine No.  from the drop down list which displays all machines which have jobs defined for them. All related fields are displayed. Select Parameter Code from those displayed in the parameter grid on the Parameter tab. You can modify details for the parameter only if no readings have been taken for it.  Changes made are  reflected in the Work Order QAP.  Select the required tab from Detail, Sampling, Data Access, Limits and Charts.


QAP Mod - Detail
The Detail Tab

On the Detail tab, you can modify all fields other than Parameter Code and Description. Select. UOM Code from the drop down list displayed from the Unit Of Measurement Master. Select Decimals from the drop down list which contains numbers 0 to 5.

 Select Parameter Type from the drop down list – whether Variable or Attributive. Unit of Measurement cannot be entered for attributive parameters. The Data Access and Limits tabs are disabled for attributive parameters.

Select Parameter Category from the drop down list – whether Critical or Optional.  If a parameter is specified as critical, at the time of Job Closure, an error message is displayed if no readings have been taken for that parameter.


QAP Mod - Sampling
The Sampling Tab

Select Sampling Technique from the drop down list – whether Sampling or 100% Inspection.

For Variable parameters:

If sampling option is selected, you must enter Sample Size and Sample Frequency.

If 100% inspection option is selected, you must enter Sample Size only. Sample Size can be 2, 3 or 4 only. Only if Pre- Control Chart option has been selected under the Charts tab then Sample Size is 1. You can enter Sample Size greater than 24 only if it is fully divisible by 5.

For Attributive parameters you must enter Subgroup Size only. If subgroup size is not fixed, you can enter 0 in this field.

Field ‘Display Cpk or Ppk value.’ added to know the system to calculate Cpk or Ppk based on the last sample numbers, if user enters 0 (zero) then system will calculate the Cpk or Ppk based on all sample. If user put the sample no 20 then system will calculate for last 20 samples.


QAP Mod - Data Access
The Data Access Tab

Select Instrument Type from the drop down list which displays all types from the Instrument Type master. Select Reading Sequence  from the drop down list – whether Continuous Reading or Interactive Reading.


QAP Mod - Limits
The Limits Tab

Select the required option from the Specification limits group box.

•	Both Sided – Parameter considers both LSL and USL. Both must be entered and USL should be always greater than or equal to LSL

•	Lower – This option is disabled.

•	Upper – Parameter considers only USL. LSL cannot be entered. It is set to 0.

Select the required option from the Control limits group box.

•	Calculate – The control limits are calculated by the system.

•	Specify – You want to specify the control limits.

If you select the Calculate option, then you must also select the appropriate option from Initial Calculation Of Control Limits group box.

•	Use LSL and USL – The Specification Limits are considered as the initial control limits.

•	Calculate using 75% of nominal difference – The control limits are calculated on the basis of 75% of the Nominal Difference. Please also refer to the Formula used for calculation of control limits.

UCLx, LCLx, LCLr and UCLr are calculated automatically depending upon the specified calculation methods.

You may enter the No. of samples for limit calculation.  If number of samples for limit calculation entered is greater than 0 and you want the control limits to be calculated repeatedly then you must check in the Repeated Calculation edit box. You may enter the Nominal Value and the Setting Value. Nominal value should be between LSL and USL. In case Lower option has been selected, Nominal value should be greater than or equal to LSL. In case Upper option has been selected, Nominal value should be less than or equal to USL.


QAP Mod - Charts
The Charts Tab

On this tab, you may specify the type of control charts you would like to view. You can select the charts based on type of parameter – whether variable or attributive. If no charts are selected and you click Save, an error message is displayed. At least one chart must be selected.

Charts available for Variable Type Parameters are:

•	X Bar R chart

•	X Bar S chart

•	Histogram

•	Pre-control chart (disabled)

•	X chart

•	X MR chart

•	Pareto Chart

•	Median Chart

If 100% Inspection option has been selected on the Sampling tab, then X Bar R Chart and X Bar S Chart cannot be selected.

Charts available for Attributive Type Parameters are:

•	P chart

•	nP chart

•	U chart

•	C chart

Depending on the Subgroup Size you have set on the Sampling tab, attributive charts can be selected. If Subgroup Size is greater than 0 then all charts are available. If Subgroup Size is 0 then only P Chart and U Chart are available. P and nP charts fall under ‘Based on Defectives’ group. U and C charts fall under ‘Based on Defects’ group. Charts can be selected under one group only.


Deletion - Job,WO,Parameter
Deletion Of Job, Work Order Or Parameter

Click Delete to delete the currently selected record. If some readings have been taken for the parameter, it cannot be deleted. If the parameter which is deleted is the only one existing for a particular job, then the related Job and Work Order also gets deleted.


Measurement Screen

 Assign Roll Number Facility

In Roll Number Tab, there are two frames (‘Current Roll Number’ and ‘Next Roll Number’) that are displayed each containing drop down lists for Machine Number, Product Code, Pass code, Batch Number and Roll number.  The user can enter information of the next roll number to be processed in the frame ‘Next Roll Number’ by selecting values from the drop down lists provided.

When user clicks the ‘Assign roll No’ button then all information from the frame ‘Next Roll Number’ is assigned to ‘Current Roll Number’ frame. The ‘Next Roll Number’ frame is cleared. Now user can enter the next roll number to be processed. The readings received are stored against the Current Roll Number.

Getting Readings (Data) From Various Instruments.

PCS system and SCADA system will collect the readings (data) from various instruments located at different locations for every second and after one minute creates a file with collected data. Every minute QMS systems gets the data from these files and stores it into database for analysis.

SPLICE Signal

When Splice takes place QMS will automatically assign the next Roll Number to Current Roll No and will make the Next Roll Number blank. In Lamination process, Splice signal will not be recognized automatically by QMS. When a Roll gets over in lamination process, user should click the SPLICE button from the Roll Number Tab.

Viewing the Parameter Detail Readings.

QMS displays 64 parameters at a time in Parameter Detail Tab. Using Previous & Next buttons user can view next or previous set of 64 parameters.

Viewing the Online Charts.

At a time user can view online charts for 4 parameters. By default X charts are displayed. By Right Clicking the chart user can view other type of charts for the selected parameter.  The Next button will show the charts for next four parameters of the last parameter selected. The Previous button will show the charts for previous four parameters of the first parameter selected. The user can select up to 4 parameters for viewing charts, only from the current set of 64 parameters.


Standard QAP & Job Creation/Job Details

This screen provides the Mapped Sequence field to store the position of the parameter in the string.  It should not be duplicate. In Formula When Bilcare Flag is true then Formula should accept the Cell Reference.  When user does Copy, Paste Or Clone then Mapped sequence needs to be taken care. While cloning or paste consider mapped sequence as part Para sequence.

In Change Sequence of Parameters Screen - Provide one more column of Mapped Sequence. User can modify the Mapped sequence through this screen.


Location Parameter Report

The Location Parameter Report displays the Location Wise Parameters. In this Report, it will display the Location Wise Parameters.


Location-Employee-Shift

The Location Employee Shift screen displays the List of Employees, Start Time and the End Time.  If the Employee is on half day then the user can change the Start time or End Time.


Datewise Location Employee Report

The Datewise Employee Report displays the List of Employees, Start Time and the End Time.  This report will display the Datewise Shift Employee Start Time and End Time. And also this report will display the Location wise date, shift Employee Report.


Change Sequence Number

Change Sequence of Parameter Screen provides one more column of Mapped Sequence in case of Bilcare. The user can modify the sequence number of parameters through this screen.


Change Mapped Sequence Number

The Changed Mapped Sequence No should be displayed in the parameter detail screen. The user is allowed to enter the mapped sequence no, which stores the position of the parameter in the string of the PCS or SCADA or PROTO. For Formula field it should accept the Cell Reference e.g. A12, C13 etc of NDC parameters.


Non Conformity Reports

Click on Non conformity Reports; which displays the screen for accepting nonconformity, select from date, to date from time, to time, machine no, part code, process code and click on Ok command button. It will launch the Job selection screen display the following details i.e. Job No, Machine, Part, Process, and Status: - whether it is current job or History Job. The user can select the Job by selecting the row. Depending upon the selection of job Batch no & Roll No combo will get filled up.

If user is not selected Batch No and Roll no then all parameter will be display on parameter selection screen, which has variation irrespective of batch no & roll no.

If user is selected Batch No then all parameter will be display on parameter selection screen, which has variation of selected batch no.

If user is selected Roll No then all parameter will be display on parameter selection screen, which has variation of selected Roll no.

If user is selected Batch No & Roll No then all parameter will be display on parameter selection screen, which has variation of selected Batch No & Roll no.

If user selects specific parameters on parameter selection screen and click on ok it will display the nonconformity report of selected parameter only.

If user does not select any parameters on parameter selection screen and click on ok it will display the nonconformity report of all parameters, which are, exist in the grid.


Rename Roll No

The user enters the old Roll No and the new Roll No and clicks on Ok button, it checks the Roll No exists or not. If it does not exist give the error message ‘Roll No is not processed’. If it is exist then ask the user Are you sure you want to rename the roll no? If the user click on yes then check if the new roll no entered by the user exist if yes then display message "Cannot update new roll no exist" if the new roll no does not exist update the Old Roll Number with New Roll No in the Job Reading table and message is displayed Roll Number is renamed from 99A to 999.


Configurable Parameter Screen  - Ignore Readings

Select Option → Settings → Configurable Parameters for accepting Percentage of Specs Limit for Ignore Readings.

Click Modify to modify the following details.

Percentage of Specs Limit for Ignore reading – The percentage of Specs Limit for Ignore readings.

Value to be display on the display board – Select the value to be display on the display board which contain Cp-Cpk-Pp-Ppk.

Click Save to save modification. Click Cancel to cancel a modification.

User can Add the above details only if no record is exists.


Trend v/s Rejection Report

You may generate a "Trend v/s Rejection report" by selecting the job from Local/Global monitoring screen and click on Trend V/S Rejection report from Report menu.

Trend V/S Rejection report shall display the reading of trends of the variable parameter of the selected job.

Select the date, time in the Search Engine Screen and then click on Ok button. If data is not available for the selected date & time then it will display the message as ‘No Trends are raised for the parameter(s)’. If data is available for the selected criteria it will launch the Trend V/S Rejection Report.

This report provides when and what trend has been raised, what corrective action has been taken and display readings as:

When reading is Out of Specs Limit then it will display as rejection. Color will display as Red.

When Sample has trend then it will display which trend has been raised & if sample is within control limit then color will display as green.

When sample is out of control limit it will display in Fuchsia color.


 TVS Delphi Report - MSA

Gauge R & R Data Analysis

Use this option to analyze the results of the study carried out for the gauge i.e. Instrument. You can also view Percentage R&R result using the Average And Range method and ANOVA method.

Completed studies from all the stations are displayed in this screen. Completed studies are those studies for which all trials have been completed using the Gauge R&R Mapping option. If no Gauge R&R study has been closed from any station then the message ‘No studies have been closed’ is displayed.

Select Station No. from the drop down list which displays all stations from which Gauge R & R study has been carried out and completed. Select Instrument Code from the drop down list which displays the  instruments for the selected Station No. for which studies have been closed. Select Part Code from the drop down list which displays the related parts for the selected Station No. and Instrument Code. Select Parameter Code from the drop down list which displays the related parameters for the selected Station No., Instrument Code and Part Code.

The Process Variation or Tolerance value options are visible on the screen only if a value has been entered for these respectively for the selected study while mapping.

If only Tolerance value has been entered for the selected study then on the Data Analysis screen the Total Variation and Tolerance options are visible. If Process Variation has been entered then Total Variation and Process Variation options are visible.

If both the values are entered for the study then all the three options are visible on the screen.

Select the required option from Total Variation, Process Variation or Tolerance. Total Variation is selected by default. You may select Process Variation or Tolerance only if values have been specified in the related fields for the selected record in the Gauge R & R Mapping  screen.

Study Date, End Date (i.e. the date when the last trial was taken), calculated values of % R & R (Average and Range Method) and % R & R (ANOVA Method) for the Station No, Instrument Code, Part Code and Parameter Code are displayed in the grid based on selection of Total Variation, Process Variation or Tolerance options.

   Click Export to Excel to view the Gauge R & R Report in Excel with the following details.

Study No is blank, Date displays the study date, IMTE code displays Instrument type. SL. No displays instrument code. IMTE description displays instrument type description. Range for which the study is valid: - N/A remains as it. Component No displays Part No, Description displays part description. Specification displays the master value ± half of tolerance. I.e. For e.g. if tolerance is 1 and master value is 3.9, then for specification displays 3.9±0.5 microns. Least Count displays the least count for the instrument. Under Inspector A, Inspector B, Inspector C it displays the operators name. For the first operator it will display the first trial in the Ist column for 10 reading. 2nd trial in the 2nd column for 10 readings. 3rd trial in the 3rd column for 10 readings. Similarly for the 2nd, 3rd operator

This facility needs to be used only for 3 operator and 3 trials.

Click Avg & Range Report to view the Gauge R & R Report (Average And Range Method).

Click ANOVA Report to view the Gauge R & R Report (ANOVA Method).

Click Chart to view the Chart for Gauge R & R.


Daily Cp,Cpk Report

Use this option to generate a  Daily Cp Cpk/ Pp Ppk Report that will display the Cp cpk or Pp Ppk details for all the selected parameters defined in all the Job or work orders created between the specified period.

Click on Report -> Daily Cp Cpk/ Pp Ppk Report menu item. A screen for accepting report Dates will be launched.

Specify the required period by entering Period From and Period To. Select the required Parameter from the parameter list. Select Cp-Cpk data or the Pp-Ppk data as per the requirement. Click OK to confirm the selection and proceed with the generation of report. Click Cancel to exit.

Report will display company name and report name in the report title. Right hand corner of report will display current date in dd-mmm-yyyy hh:mm:ss AM/PM format. From and To Date selected from the Report dates screen will be displayed.

This report will display the Parameter names, date of Job/WorkOrder creation, Part no, Workorder no, Machine no, Operator code, Process code, Cp and Cpk or Pp and Ppk. Cp and Cpk or Pp and Ppk will be categorized under three columns - >1.33, 1.33, <1 each.

Cp or Pp column will not be display when the parameter is single sided.

The report footer will have Monthwise total of the workorders, and Cp&Cpk or Pp & Ppk totals. And also the grand total of the overall data for all those Jobs that have been created in the selected date range.

User can close the report by clicking its control box or Close toolbar button or menu item.


Parameters Cp, Cpk report

Use this option to generate a Parameter Cp Cpk/Pp Ppk Summary Report that will display the summary of all readings and Cp Cpk or Pp Ppk details for the selected parameter defined in all the Job or work orders created between the specified period.

Click on Report -> Parameter Cpk/Ppk Summary Report menu item. A screen for accepting report Dates will be launched. Specify the required period by entering Period From and Period To. Select the required Parameter from the parameter list. Select Cp-Cpk data or the Pp-Ppk data as per the requirement. Click OK to confirm the selection and proceed with the generation of report. Click Cancel to exit.

If the user had selected Cpk, the report launched will be Parameter Cp-Cpk Summary report with all the readings, Range, Read (+/- 3 Sigma) and Cp-Cpk data for the parameter selected.

Similarly if the user had selected Ppk the report launched will be Parameter Pp-Ppk Summary report with all the readings, Range, Read (+/- 3 Sigma) and Pp-Ppk data for the parameter selected.

If there are no Workorders/Jobs created between the selected period, which contains the selected parameters, then the message is displayed as "Data not available for the parameter(s) in the selected period". And the user can choose some other parameters or can change the time period.

If user clicks Cancel button then screen for accepting report dates will close without displaying any report.

User can also close screen for accepting report dates by clicking its control box or Close toolbar button or Close menu item.


 Import data from Excel

You can import reading data from an excel file and provide the facility for the statistical analysis using the tools provided by PROQMS.

The screen also provides a facility to select parameter details to create QAPs, Jobs and calculate Cp, Cpk, Pp, and Ppk at the background.

   Click on File -> Import Data menu item. A screen for accepting data required for the Import will be launched.

Select Parameter code and Parameter Type. The user has to select the Parameter Type – Attributive or Variable. Depending on the Parameter type the user has to define/select certain properties of variable or attributive parameters and the charts.

   If Variable type is selected then the Variable properties of the parameter will be enabled for the user to select or

   enter-

•	Decimal - By default the decimal place will be set to 4. The decimal places should be from 0 to 5 only.

•	UOM - By default the UOM will be set to MM

•	Tolerance - Tolerance is set to Both side by default. The user can change it to Upper side also.

•	The user has to specify the LSL, USL and Nominal values. If Upper option is selected then LSL will be disabled. The value of LSL will be 0.

•	Nominal Value - The Nominal value should be less than or equal to USL.  In case of Both Sided option, USL should be always greater than or equal to LSL. Nominal value should be between LSL and USL.

•	Inspection Technique - By default the Inspection Technique will be set to Sampling. The user can change it to 100% Inspection mode also.

In case of Sampling, Sample size will be enabled and it will accept value greater than 1. User cannot enter 0 for Sample Size. The sample size is set to 5 by default .If Sample Size is greater than 25 then it is acceptable only if Sample Size mod 5 = 0.

If 100% inspection option is selected then Moving Range Size will be enabled in place of Sample Size. For 100% Inspection, the Moving Range Size can be 2,3 or 4.Bydefault the Moving range will be set to 3.

•	Charts - For variable type of parameter, X Bar R Chart, X Bar S Chart, Histogram, X Chart, X-MR chart and Median Chart can be selected. If 100% Inspection under Inspection technique has been selected then X Bar S chart under chart tab will be disabled and deselected and only Histogram will be selected by default. If Sample Size is greater than 10 then Median chart option will be disabled and deselected. If Sampling is selected then by default the Histogram and X bar R chart are shown selected.

        If Attributive option is selected then the Attributive properties of the parameter will be enabled for the user to

        select or enter –

Subgroup Size

Charts -

For Attributive type of parameter, P chart, Np chart, U chart and C chart can be selected. If subgroup size is greater than 0 then all charts P, Np, U and C are enabled. If user selects P chart or Np chart then U and C chart are disabled. Similarly, if U chart or C chart is selected then P and Np chart are disabled.

If Subgroup Size is 0 then P Chart and U Chart options are enabled, Np and C chart are disabled. If the user selects P chart then U chart is disabled and if U chart is selected then P chart is disabled.

Select the Excel file from where the reading data wants to import. Click on the "…" button provided to open a file dialog box. Select an .xls file. After the file is selected, the user can either specify the range of data to be selected or select print Area.

After selecting the file and specifying the range Click on Import button, if no errors then display the ‘Data successfully imported in Job Date and Current time’ and display the Import Monitoring screen. User can select the job and try to launch the measurement screen to see the chart details.

Part COde,Process Code,Parameter Code, Machine No. and Job date fields are provided for the user selection. If user selects Part,Process and Parameter which is exist in Qap then software display the message 'Duplicate QAP' and populate the respective controls from the the existing QAP.


Process Capability Study Reports

Use this option to generate a Process Capability Study Report for the specified criteria so that in one go, supervisor can see the Process Capability details for the selected Jobs

Click on Reports · Process Capability Study Report, (Date Selection Screen) is launched on the click of OK will launch Process Capability Study Report.

OR

Click on Reports · History · Process Capability Study Report, History Readings screen is launched on the click of OK will launch Process Capability Study Report.

The user can select period from & period to.  Machine No will get populated depending upon the selection of dates.  Part Code will get populated depending upon the selected Machine No. Process Code will get populated depending upon the selected Part Code. Click on OK button, which will launch the excel report.

If Cpk value is less than 1.33 then Cpk value display on excel cell should be in red color (fore color) and all other columns will display in Normal color (Black) in case of Greaves only else all columns will be in black and also Header of Excel sheet should be Location description (which is in link with Machine No) of 1st Job [Selected] from Monitor screen.


 Process Capability Study Reports Run Chart

Use this option to generate a Process Capability Study Report Run Chart for the specified criteria so that in one go, supervisor can see the Process Capability-Run Chart details for the selected Jobs.

Click on Reports · Process Capability Study Report-Run Chart,  (Date Selection Screen) is launched on the click of OK will launch Process Capability Study Report-Run Chart.

OR

Click on Reports · History · Process Capability Study Report-Run Chart, History Readings screen is launched on the click of OK will launch Process Capability Study Report-Run Chart.

The user can select period from & period to.  Machine No will get populated depending upon the selection of dates.  Part Code will get populated depending upon the selected Machine No. Process Code will get populated depending upon the selected Part Code. Click on OK button, which will launch the excel report.

If Cpk value is less than 1.33 then Cpk value display on excel cell should be in red color (fore color) and all other columns will display in Normal color (Black) in case of Greaves only else all columns will be in black. This will be done for both jobs current & closed.

Header of Excel sheet should be Location description (which is in link with MachineNo) of 1st Job [Selected] from Monitor/Global Monitor screen.


Process Capability Study Reports Histogram

Use this option to generate a Process Capability Study Report Histogram for the specified criteria so that in one go, supervisor can see the Process Capability-Histogram details for the selected Jobs

Click on Reports · Process Capability Study Report-Histogram, (Frmchartdates) is launched on the click of OK will launch Process Capability Study Report-Histogram.

OR

Click on Reports · History · Process Capability Study Report-Histogram, History Readings screen is launched on the click of OK will launch Process Capability Study Report-Histogram.

The user can select period from & period to.  Machine No will get populated depending upon the selection of dates.  Part Code will get populated depending upon the selected Machine No. Process Code will get populated depending upon the selected Part Code. Click on OK button, which will launch the excel report.

If Cpk value is less than 1.33 then Cpk value display on excel cell should be in red color (fore color) and all other columns will display in Normal color (Black) in case of Greaves only else all columns will be in black. This will be done for both jobs current & closed.

Header of Excel sheet should be Location description (which is in link with Machine No) of 1st Job [Selected] from Monitor/Global Monitor screen.


All Parameter Reading Report for more than one job

   All Parameter Reading Report (Different Jobs – One Part) display information of selected jobs that cover Part code,

   Part Name, Job No, Process, Machine, Parameter, USLValue, LSL Value, Reading Serial No, Readings on Excel sheet.

  User can see the record of multiple jobs with all parameter of different job for one part at a glance.

Click on Reports · All Parameter Reading Report (Different Jobs – One Part) will launch Date Selection screen and on OK

Click on Reports · History · All Parameter Reading Report (Different Jobs – One Part) will launch History Reading screen, select data and click on OK


Overview of Email and SMS facility

Email/SMS Facility in PROQMS

Email & SMS facility in ProQMS gives the information about trends that are raised during inspection. All trends that are raised, during certain interval of time will send trend count through SMS and customized message through Email to configured users.

Trend information is available on individual E-mail Id or Mobile No and also to send trend information which is pending for corrective action to Unit Manager, General Manager, and President.

If user right click the icon of E-mail & SMS system, Six options will be available i.e Start Email, Start SMS, Stop Email, Stop SMS, Configuration and Exit.

During startup, ‘Start Email, Start SMS’ is enabled and ‘Stop Email, Stop SMS’ is disabled that means no any service like Email or SMS is running.

After click on ‘Start Email’, this will get disabled & checked & Stop Email will get enabled & unchecked. E-mail system starts the working i.e. to search the trends for particular interval of time (i.e. time assigned in company master) that are assigned by the user & send all trends with machine, station, part related information to assign mail id.

G_EmailSCL = True

When application will get start, system will show 4 menus like Start E-mail, Stop E-mail, Configuration and Exit.

When user click on Start E-mail, based on Email Frequency, system will gather the information for trend which are pending for corrective action and create pdf file for same and send the mail to relevant unit manager for a cell. At the same time based on unit manager/general manager frequency, system will gather the information for trend which are pending for corrective action and create pdf file for same and send the mail to relevant general manager/president. While sending a mail to general manager, system will also send the mail to unit manager of general manager. In a day, system will send one mail to general manager & president.

When email frequency get elapsed then system will gather the information for trend which are pending for corrective action and create pdf file for same and send the mail to relevant unit manager for a cell.

System will send the mail even if No trend for pending correction action available.

Before sending mail to General Manager or President, systems will checks for current date mail has been sent or Not.

SMTP is used for sending Email.

After click on ‘Start SMS’, this will get disabled & checked & Stop SMS will get enabled & unchecked. SMS system start the working i.e. to search the trends for particular interval of time that are defined by the user & send all Trends No to Mobile No that are defined in the database w.r.t. Shift.

After Selecting Configuration menu from the tray-icon of Email/SMS and by entering valid user name & Password, following options are available.

File

Configuration.

Click on file -> Exit, form will get unloaded.

Click on Configuration, following options are available.

Email SMS Contacts User

Email SMS Configure Frequency

Email SMS Configure Web User

Email SMS Configure Sender Email Id

Email SMS Configure Shift User

Email SMS Configure User Machine


Email SMS Contacts User

Use this option to enter different Email user like - Email Id, Mobile No, Shift Change SMS (alert), Category and Desktop Frequency for sending Trend related information via Email & SMS.

Click Add to add a new entry. Enter the following details:

Name – The name of the user.

Email Id – The Email Id of the user.

Select option to choose mobile category.

GSM

CDMA

User needs to select one of the mobile categories to enter the mobile number or to select ‘Shift Change SMS’.

•	Mobile No – Mobile number of the user.

•	Shift Change SMS – This indicates "Shift Change SMS" (alert) for changing the shifts of the user in Email/SMS application.

•	Category - Pre-defined category of the user. i.e. President, General Manager, Unit Manager and None.

•	Desktop Frequency – Frequency for sending Trend related information via Email.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You cannot delete a user if it is used in the Configure Shift User Screen


Email SMS Configure Frequency

Use this option to modify Email & SMS frequency, Shift Change day & time, Unit Manager Frequency, General Manager Frequency, and Pending Days for Non Conformity Frequency. This data will require during sending E-mail & SMS.

Click Modify to modify the configure frequency for the following fields.

Email Frequency – Email frequency in minutes.

SMS Frequency - SMS frequency in minutes.

Shift Change day – Select the shift change day from the drop down list.

Shift Change Time – Enter shift change time.

User can specify Unit Manager Frequency, General Manager Frequency, Pending Days For Nonconformity Frequency.  This will be used if the Unit Manager or General Manager has not taken the corrective action within specified frequency, email will be sent to GM or President.

Click Modify to modify details. Click Save to save modification. Click Cancel to cancel a modification. Click Delete to delete a record


Email  SMS Configure Web User

Use this option to add only one Web User, Password, and Sender ID for sending Trend related information via SMS. Product use the third party tool from snowwebs.com for sending SMS. For sending SMS Internet connection is required.

Click Add to add only one record. Enter the following details:

User Name – The User name

Password – User Password

GSM Sender Id – Enter GSM sender ID for GSM mobile category.

CDMA Sender Id - Enter CDMA sender ID for CDMA mobile category.

Click Modify to modify details. Click Save to save a record or modification. Click Cancel to cancel a modification or addition. Click Close button, Active form will get unloaded


Email SMS Configure Sender Email Id

Use this option to add only one User, Sender E-mail Id, Host Name and Port for sending trend related information via Email.

Click Add to add only one record. Enter the following details:

User Name – The User name

Sender Email Id – Email Id of the sender.

Password –Password of Email Id for whom mail will send

Host Name – The Host Name

Port – Port Number

Click Modify to modify details. Click Save to save a record or modification. Click Cancel to cancel a modification or addition. Click Close button, Active form will get unloaded.


Email SMS Configure Shift User

Use this option to maintain a relation between shift and User.

User can add/modify/delete Shift, User. This data will require to distinguish shift wise user.

Click Add to add a new entry. Enter the following details:

Shift Code – Select the shift code from the drop down list.

Name – Select the User.

Click Modify to modify details. Click Save to save a new record or modification. Click Cancel to cancel a modification or addition. Click Delete to delete a record. You cannot delete a user if it is used in the Configure User Machine Screen


Email SMS Configure User Machine

Use this option to maintain a relation between User and Machine.

User can add/modify/delete Machine and User. This data will require to allocate machine user wise.

Click Add to add a new entry. Enter the following details:

Name – User Name

Machine No. – Select the Machine Number

User can select the following options as per the requirement.

All Shift Report

Shift Report

Regular E Mail

Regular SMS

Shift Report/All Shift Report display information of trend raised for a machine during the shift that cover Shift, Shift Time, Station No, Machine No, Machine Name, Part No, Part Name, Job No, Process Code, Process Name, Parameter Code, Trend Description, Sample No, Sample Date, Sample Time, Responsibility Assigned To, Target Date, Corrective Action taken Date, Corrective Action, Root Causes, Remark which is export from crystal report to Acrobat file (.pdf).


Station-wise All Parameter reading report for all the job of selected Date & time

Use this option to generate a All Parameter Reading Report (Station wise) which displays information of all jobs that come under selected period for selected station no that cover Part code, Job No, Process, Machine, Parameter, USL Value, LSL Value, Reading Serial No, Readings on Excel sheet

Clicks on Report-> All Parameter Reading Report (Station Wise)

All parameter reading report form will get launch with From Date, From Time, To Date, To Time with current date & current time & Station No list box that contain no record.

Station No list box will get filled when selected period have readings.

Click on Cancel button or close (X) form will get unloaded.

Click on Ok button, report that is in the form of excel get launch depending upon the selection of date & station no.

In Excel, each sheet contains all jobs that come under one station no for selected period that is arranged job serial no wise.

Report contain Company Name at the top of the sheet, Report Name, Report launch date, from date, to date & detail field contain Job No, Part Code-Description, Process Code-Description, Machine, Parameter Code-Description, LSL, USL, Reading Serial No.

History job will be identified, by adding the History word after the Job No


Provide user interface for Resending Trend Email

Resend Trend Email – (Manual)

Clicks on Report-> Resend Trend Email-> Manual [More than one Machine], Resend Trend Email form will get launch with Date as current date & Shift No list box that contain all shift from master & MachineNo list box contain machine for selected date. When user click on Cancel button form will get unloaded.

When user click on OK button, trend for selected date, shift, machine will gather & convert this into .pdf file and then default mail client will get launch with currently created pdf file as an attachment & predefined subject, body message  & To, CC, BCC is empty to enter email id that user want to send the mail.

After sending mail display message ‘Email Send’

If no trend found for selected date, shift & machine message will display ‘No Trend Raised’. Report contains report name, company name, report date, shift, shift time, station no, machine no, part no, process no, parameter & its description, job no, sample no, sample time, trend description etc.

Resend Trend Email – (Automatic)

Clicks on Report-> Resend Trend Email-> Automatic [One Machine], Resend Trend Email form will get launch with Date as current date & Shift No list box that contain all shift from master & Machine No list box contain machine for selected date.

Click on Cancel button form will get unloaded.

Click on OK button, trend for selected date, shift, machine will gather & convert this into .pdf file & then mail will go with currently created pdf file as a attachment, predefined subject, body message and predefined mail id which is based on shift & mail id.

After sending mail display message ‘Email Send’

If no trend found for selected date, shift & machine message will display ‘No Trend Raised’.

Report contains report name, company name, report date, shift, shift time, station no, machine no, part no, process no, parameter & its description, job no, sample no, sample time, trend description etc


 Instrument Calibration Master - Instrument   Steps Code Min    Max

Click → Configuration → Instrument Calibration

Use this option to add different Instrument No, Cal Step Code, LSL, and USL for creating relationship of Instrument with Calibration Step Code with LSL & USL.

Click Add, to add new record. Modify, Delete, button will get disabled & save, cancel button will get enabled and All Calibration step code gets loaded into grid.

Click Save button i.e Add, Modify, Delete button will get enabled & Save, Cancel button will get disabled and all Calibration step code that has checked or selected along with its LSL, LSL value for selected instrument will get saved.

Click on Modify, to modify an existing record i.e. Add, Delete, button will get disabled & save, cancel button will get enabled and All calibration step code along with entered LSL, USL will get display so that user can enter or change the LSL, USL value.

Click Delete button. Add, Modify, Delete button will get enabled & Save, Cancel button will get disabled and system will check that instrument no is used in History calibration or Not, if Not then delete the Instrument No from Instrument Calibration Master if instrument no is used then display the message  "Cannot Delete. Record exists in Gauge Calibration"


Instrument Calibration History - Calibration Frequency, Steps, Min, MAx   Wear Value

Gauge Calibration

Click Monitoring → Gauge Calibration

Use this option to record and maintain the Calibration details for an Instrument.  The Calibrated Date, Next Calibration due date, whether it was calibrated In house or Outside, if outside then which company and the remarks, all these details will be maintained for the selected Instrument.

User can also enter wear value of an instrument for defined step code.

Depending on the rights assigned to the user, the user can add the Calibrated details.

•	Instrument Code - select required Instrument Code.

   The description of selected instrument will be displayed in the description text box.

•	Calibrated Date - Calibrated date displayed will be the last calibrated date for the instrument. The user will modify calibrated Date by selecting from the calendar displayed after clicking on Calibrated Date date picker. The selected calibrated date can neither be less than the last calibrated date for the instrument nor it can be greater than the system date.

Next Calibration Date – It will be always greater than Calibrated date and System Date.

•	Calibrated – Select one of the option button – In house or Outside

If Outside then the user will enter the Company Name in the Company Text box else if In house then the Company name will remain as In house itself.

The user may or may not enter any remarks in the Remarks text box.

Click on Save.

The Calibration due date also updates the Instrument screen’s calibration date field.

After selecting the instrument no, calibration frequency will display in frequency text box. After entering the calibration date, calibration due date will calculate based on calibration frequency & display in calibration due date Date Picker.

In a grid user can enter wear value for step code.

Modify Mode

The user is allowed to modify only the Calibrated details i.e. In house or Outside and the Remarks if any.

User can select the instrument from the Instrument combo and the Calibrated date from Calibrated date combo. For the selected record the user can modify the Remarks and the Calibrated details.

During modify mode all calibration details for selected instrument will display and user can change wear value.

Save Mode

The user can save the record after Add or Modify Mode. If some invalid data has been entered in Add/Modify mode then at the time of saving the record, appropriate validation message will display and record will not be saved. On saving the record after Add mode, the added record is displayed. On saving the record after Modify mode, the modified record is displayed.

In Add/Modify mode, user will enter or change the wear value for all step code.

Cancel Mode –

The user can cancel the changes before saving the record, when in Add or Modify mode. On canceling the record when in Add mode, the first record will display. On canceling the record when in Modify mode, the record being modified will display.

View Mode –

In the View mode, Instrument code combo and Calibrated Date combo will be enabled state and all other controls including grid on the screen will be in disabled state. All the Calibrated dates for the instrument will be populated in the Calibrated Date combo. The User can select any instrument and any calibrated date for the instrument and view it’s details.

When Gauge Management flag is true then only user can see the following fields.

Reference Standard used - Reference Standard used for Calibration.

Calibration Report No 	- Calibration Report of the Instrument.

Gauge Accepted	- Calibration of Instrument is accepted Yes or No.


Instrument Calibration History Report

Click on Report → Gauge Calibration → History Calibration

Use this option to generate Instrument Calibration History Report which displays information of Instrument No, Calibration date, Calibration due date, Calibrated In house /Company, Remarks, Step code, Description, LSL, USL, Wear Value


 Wear Trend Analysis

Click Monitoring → Gauge Calibration → Wear Trend Chart

It displays the information when calibration of instrument is done and what is the wear value of the step code and depending upon the collected information predicted failure could be calculated based on the standard formula.

Chart contain Wear value on Y axis  & Calibration date on X axis

Calibration date and wear value also get display while plotting the Charts at the bottom.


The Control Chart

To view this tab, user must select only one parameter by checking in the Chart field on the Readings tab.

In this tab, user is able to view the following charts along with the readings (in samples) on one screen.

Histogram. (For all readings.)

XbarR Chart, X Chart and X-MR Chart (For the No. Of samples selected in the Company Settings.)

Grid with Readings. (For the No. Of samples selected in the Company Settings.)

Following Statistical Analysis is displayed for the selected charts.

Capability Indices – Cp and Cpk values

Specifications – USL (Upper Specs Limit), LSL (Lower Specs Limit) and N (Number of readings)

Out of Specifications – Above and Below (Number of reading which are above and below the specifications)

Max – Maximum value reading

Mean – Average value

Min – Minimum Value reading

DPM – Value gets calculated using SPC formulae. Refer SPC formulae.

Skewness - Value gets calculated using SPC formulae. Refer SPC formulae.

Kurtosis - Value gets calculated using SPC formulae. Refer SPC formulae.

The number of points displayed in the online chart depends on the value entered for display of online points in the Company Settings screen.

Grid column will vary as per the No of samples and the Grid Row will vary as per the Sample Size. When user move the mouse over the Sample in the chart then the corresponding column of grid gets highlighted.

For all Line Charts: To view details of all actual readings for the samples, use the mouse to move the cursor to the points plotted on the chart. The application will display Sample No., Date, Time, Readings for each reading.

Scroll Buttons are provided for scrolling next or Previous Samples. When user move the mouse over the Sample in the chart then the corresponding column of grid gets  highlighted.

Cp, Cpk or Pp, Ppk Value {Based on Last Sample No] –

For selected parameter user configure ‘Display Cpk or Ppk value’ to zero then system will calculate the Cp, Cpk or Pp, Ppk for all sample no and for greater than zero then system will calculate Cp, Cpk or Pp, Ppk based on last sample no. Process Status will also display the color depends upon the Display Cpk or Ppk value in Dashboard for last sample numbers.

On delete operation system will check above condition and do the calculation.

Angle Parameter –

If parameter is of type Angle then user tries to move the mouse pointer on Sample then reading will display in both format i.e. Angle & decimal.  This is done for X, X-MR, X Bar R and X Bar S Chart.

In grid all the reading value show in decimal rather parameter UOM is angle or not. If user want to see reading in grid as degree then use has to checked Show Angle checkbox otherwise reading in grid will display in decimal.

In case of Histogram chart & its readings will display in decimal whether parameter UOM is angle or Not & Show Angle checkbox will make visible false.

Print Label as CL in histogram. Value of Centerline will be the Nominal value of that Parameter.

Centerline would be red in color and the label would be CL

Mouse Move Facility on range –

If the online chart displayed is XbarR chart and user clicks on the sample in Xbar area then for the sample it displays the following details i.e.Sample no, Xbar, Date, time, Readings. If the user moves the mouse pointer on the sample in Range area then for the sample it displays the following details i.e.Sampleno, Rbar, Date, time, Readings.

If the online chart displayed is XMR user clicks on the X area it displays the following details i.e. Reading, Date, and Time. If the user clicks on MR area then for the sample it displays the following details i.e. Moving Range, Date, Time


The Bar Display tab (Measurement)

Bar Display tab will display one bar for each parameter selected from Local Monitor screen. It will display Bar image, Reading, USL, LSL, Parameter and the process vertically (one below the other).

If reading is less than LSL, bar will be displayed with Yellow Color.

If reading is Greater than USL, Bar will be displayed with Red Color.
If reading is within Specification Limit, Bar will display Green Color

Top portion of the Bar Display Tab will display following information: -

Operation – Display Location from Machine Master for machine set for selected job/s. [Location]

Machine – Display Machine from Job.

Die Code  - Die Code that has been set for Part-Machine of selected Jobs otherwise NA

Comp. Code – Part Code field from Part Master screen.

Revision No & Date  - Drawing File field from Part Master screen.

Insp. Name – Login Name

Supr. Name – Supervisor Name combo box will be enabled and non editable

User can view Only 28 parameters because of the limitation of the Screen width


Dashboard Tab

If for selected parameter, sampling Technique is ‘Sampling’ then Tab caption will display ‘Cp/Cpk’

If for Sampling Technique is ‘100% Inspection’ tab caption will display ‘Pp/Ppk’

For mixed parameter tab caption will display ‘Cp/Cpk’.

Displaying Cp, Cpk or Pp, Ppk value on button check-

The value is below of configure Cpk or Ppk value (in trend setting screen) if it is less then that button will display in Red color and in feedback Red light will get display.

The value is above of configure Cpk or Ppk value (in trend setting screen) if it is greater then that button will display in Green color and in feedback Green light will get display.

Total Parameters to be display –

If parameter count is greater than entered value in ‘Total parameter to be display’ textbox then Next button will get enabled.

If parameter count is less than entered or available value in textbox then Prev & next button will get disabled.

Maximum 12 parameters will get display.

Cp, Cpk or Pp, Ppk Value {Based on Last SampleNo] –

On dashboard Tab, for a parameter ‘Display Cpk or Ppk value’ to zero then system will calculate the Cp, Cpk or Pp, Ppk for all sample no and for greater than zero then system will calculate Cp, Cpk or Pp, Ppk based on last sample no. Process Status will also display the color depends upon the Display Cpk or Ppk value in Dashboard for last sample numbers.

Cp/Cpk Display on Display Board –

After completion of each sample or after every reading for each parameter Cp, Cpk, Pp, Ppk (whichever is  configure in Configurable Parameter) is to be display on display board


Event Remark Report

Use this option to generate Event Remark Report that will display the event remarks that have been already entered for samples and readings of selected job and all variable parameters associated with that job.

Select the job from Local Monitoring or Global Jobs screen.

Click Reports → Remarks Report menu option

For closed Jobs

Click Reports → History → Remarks Report menu option.

Search Engine Screen will launch with caption ‘Screen for Accepting Report Dates’. It will display Machine No., Part Code and Process Code selected from Local Monitoring or Global Jobs screen. Select date and time range as a selection criterion for Event Remark report display. Click OK button. If data is not available for the selected date & time then it will display the message as ‘No event remarks available for the parameter(s)’. If data is available for the selected criteria it will launch the Event Remark Report.

User has also provided the facility to take print out of Event Remark Report without displaying it on the screen for selected job and all variable parameters associated with that job. For that Print button is provided on Sample Reading screen. After clicking on Print button Print Dialog box will appear. If Ok button is clicked Event Remark Report will get printed for that job. If Cancel button is clicked then Report will not get printed. This option you can see after user add Remarks or View Remarks.

For a closed job the History Remarks Report screen will be used for launching the report


Process Capability_Study Report1

Use this option to generate a Process Capability Study Report for the specified criteria so that in one go, supervisor can see the Process Capability details for the selected Jobs

Click on Reports · Process Capability Study Report, (Date Selection Screen) is launched on the click of OK will launch Process Capability Study Report.

OR

Click on Reports · History · Process Capability Study Report, History Readings screen is launched on the click of OK will launch Process Capability Study Report.

The user can select period from & period to.  Machine No will get populated depending upon the selection of dates.  Part Code will get populated depending upon the selected Machine No. Process Code will get populated depending upon the selected Part Code. Click on OK button, which will launch the excel report.

If Cpk value is less than 1.33 then Cpk value display on excel cell should be in red color (fore color) and all other columns will display in Normal color (Black) in case of Greaves only else all columns will be in black and also Header of Excel sheet should be Location description (which is in link with Machine No) of 1st Job [Selected] from Monitor screen.


QS 9000 Report

QS-9000 report is a pre-formatted report. This report will be launched for Current and closed jobs. For current jobs Local or Global Monitor screen should be active and completed more than five samples for individual parameter. For Closed jobs History selection screen will be used.


Remark Report

Remark Report is a pre-formatted report. This report will be launched for Current and closed jobs. For current jobs Local or Global Monitor screen should be active and completed more than five samples for individual parameter. For Closed jobs History selection screen will be used.

Remark Report will display the event remarks that have been already entered for samples and readings of selected job and all variable parameters associated with that job.

Click on Reports→Remarks Report is launched on the click of OK.

OR

Click on Reports→History→ Remarks Report, History Remarks screen is launched on the click of OK will launch Remarks Report.

Search Engine Screen will launch with caption ‘Screen for Accepting Report Dates’. It will display Machine No., Part Code and Process Code selected from Local Monitoring or Global Jobs screen. Select date and time range as a selection criterion for Event Remark report display. Click OK button. If data is not available for the selected date & time then it will display the message as ‘No event remarks available for the parameter(s)’. If data is available for the selected criteria it will launch the Event Remark Report.

For a closed job the History Remarks Report screen will be used for launching the report.


Resend Trend Email

Resend Trend Email – Manual

Clicks on Report-> Resend Trend Email-> Manual [More than one Machine], Resend Trend Email form will get launch with Date as current date & Shift No list box that contain all shift from master & Machine No list box contain machine for selected date. When user click on Cancel button form will get unloaded.

When user click on OK button, trend for selected date, shift, machine will gather & convert this into .pdf file and then default mail client will get launch with currently created pdf file as an attachment & predefined subject, body message  & To, CC, BCC is empty to enter email id that user want to send the mail.

After sending mail display message ‘Email Send’

If no trend found for selected date, shift & machine message will display ‘No Trend Raised’. Report contains report name, company name, report date, shift, shift time, station no, machine no, part no, process no, parameter & its description, job no, sample no, sample time, trend description etc.

Resend Trend Email – Automatic

Clicks on Report-> Resend Trend Email-> Automatic [One Machine], Resend Trend Email form will get launch with Date as current date & Shift No list box that contain all shift from master & Machine No list box contain machine for selected date.

Click on Cancel button form will get unloaded.

Click on OK button, trend for selected date, shift, machine will gather & convert this into .pdf file & then mail will go with currently created pdf file as a attachment, predefined subject, body message and predefined mail id which is based on shift & mail id.

After sending mail display message ‘Email Send’

If no trend found for selected date, shift & machine message will display ‘No Trend Raised’.

Report contains report name, company name, report date, shift, shift time, station no, machine no, part no, process no, parameter & its description, job no, sample no, sample time, trend description etc


SPC Formulas

SPC Formulas

Standard SPC Formulas

                     _

SD = R/D2

Cp = USL – LSL / 6 * SD

Cpk = min (Cpl, Cpu)

                _

Cpl = X – LSL / 3 * SD

                            _

Cpu = USL - X / 3 * SD

SD (n-1) (for n-1 samples) = sqrt [((X12 + X22 +…Xn2) – n (XBAR)2 ) / (n-1)]

Pp = (USL – LSL) / 6 * SD (n-1)

Ppk = min (Ppl, Ppu)

                 _

Ppl = (X – LSL) / (3 * SD (n-1))

                              _

Ppu = (USL – X) / (3 * SD (n-1))

FOR  XbarR Chart :

                    _

LCLx = X – (A2 * R)

                    _

UCLx = X + (A2 * R)

UCLr = (D4 * R)

LCLr = (D3 * R)

FOR  XbarS Chart :

UCLs = B4 * S


LCLs = B3 * S

                    _

LCLx = X - (A3 * S)

                    _

UCLx = X + (A3 * S)

S = SD (n-1) for each sub-group

FOR  XMR Chart :

UCLmr = D4 * R

LCLmr = D3 * R

UCLx = X + E2 R

LCLx = X - E2 R

Chi-Square Goodness-of-Fit Test

In SPC, the chi-square statistic is used to determine how well the actual distribution fits the expected distribution. Chi-square compares the number of observations found in each cell in a histogram (actual) to the number of observations that would be found in an expected distribution. If the differences are small, the distribution fits the theoretical distribution. If the difference are large, the distribution probably does not fit the expected distribution.

Using Chi-square with the assumption of a normal distribution

1.The calculated chi-square is compared to the value in the table of constants for chi-square based on the number of "degrees of freedom."

2.If the calculated chi-square is less than the value in the table, the chi-square test passes. You can keep the assumption that the process has a normal distribution.

3.If the chi-square is larger than the value in the table, the chi-square test fails. At this confidence level, you either do not have enough data to judge the process, or you should reject the assumption that the process has a normal distribution.

For chi-square test:

Good cell defined

A cell where the expected number of observations is at least 5 based on the theoretical distribution (normal curve). If the expected number of observations is not 5 or more as per Duncan), then the cells width is increased until the expected value of 5 or more is reached. If all readings are fitting in only 1 Cell after combining Chi Square test can not be performed.

Degrees of freedom = n - 1.  where n is no of classes.

Confidence level can be set from Chart > Options to 95%, 99% and 99.1%.

Formula:

       2      K            2

 	 Chi-squareχ   = ∑ (Oi-Ei) / Ei

                              K     I=0

where K-1 is degree of freedom and K no of class intervals.

Where:

Oi  = actual frequency or number of observations in a cell

Ei = expected frequency or number of observations in a cell in the theoretical distribution

∑ = symbol for "summation."

Skewness Value

Skewness is the measure of the asymmetry of a histogram (frequency distribution).  A histogram with normal distribution is symmetrical. In other words, the same amount of data falls on both sides of the mean. A normal distribution will have a skewness of 0. The direction of skewness is to the tail. The larger the number, the longer the tail. If skewness is positive, the tail on the right side of the distribution will be longer.  If skewness is negative, the tail on the left side will be "longer."

Formulas

         N            _     3

N 	         ∑ ((Xi – X)/S)

Skewness =    --------------------  *   i =1

 	   (N-1) * (N-2)

 _

X = mean	N= No. of data points   	S= standard Deviation

Kurtosis value

Kurtosis is a measure of the combined weight of the tails in relation to the rest of the distribution. As the tails of a distribution become heavier, the kurtosis value will increase. As the tails become lighter the kurtosis value will decrease. A histogram with a normal distribution has a kurtosis of 0. If the distribution is peaked (tall and skinny), it will have a kurtosis greater than 0 and is said to be leptokurtic. If the distribution is flat, it will have a kurtosis value less than zero and is said to be platykurtic.

Formulas

            N	   _     4	     2

       N*(N+1)* ∑ ((Xi - X)/S)	      3*(N-1)

           i =1

Kurtosis =    ---------------------------             -       --------------

  (N-1)(N-2)(N-3)                         (N-2)(N-3)

 _

X = mean,  	   N = No. of data points  	S= standard Deviation

Non Parametric method for PPK Calculation

Formula:

Pp = (USL - LSL)/(P(0.99875) - P(0.00135))

Ppk = Min {(P(0.5) - LSL)/(P(0.5) - P(0.00135)), (USL –P(0.5)) / (P(0.99875) - P(0.5))}

Box Cox Transformation for CPK Calculation

Box-Cox is a method of transformation of data to make it normal or more nearly normal.

Formula:

     λ

Yi (λ) = (Xi – 1) / λ

After transformation of data using above method Cp, Cpk, Pp, Ppk is calculated with standard formulas.

λ is Calculated using log likely hood function. Which is

The logarithm of the likelihood function

  	       n               _       2                    n

      	(-n/2)LN [∑(Xi(λ)-X(λ))/n]+( λ-1) ∑LN(Xi)

          	                  I =1                                         I =1

                	_              n

Where X(λ)=1/n ∑ Xi(λ)

      	   i=1

Note-

λ value is restricted from –10 to + 10.

If data contains any negative values Box Cox Transformation can not be performed.

To run Box Cox transformation Ms-Excel needs to be installed on the machine.

PPM Calculation

Formula:

                	             _

Calculate Z upper=(USL –X)/ σ

Locate the value for Zupper in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % above the upper spec Limit.

                                                   _

Similarly calculate Z Lower=(X-LSL)/ σ

Locate the value for Z lower in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % below the lower spec Limit.

DPM=(Zupper + Zlower) * 10,000


LCLs = B3 * S

                    _

LCLx = X - (A3 * S)

                    _

UCLx = X + (A3 * S)

S = SD (n-1) for each sub-group

FOR  XMR Chart :

UCLmr = D4 * R

LCLmr = D3 * R

UCLx = X + E2 R

LCLx = X - E2 R

Chi-Square Goodness-of-Fit Test

In SPC, the chi-square statistic is used to determine how well the actual distribution fits the expected distribution. Chi-square compares the number of observations found in each cell in a histogram (actual) to the number of observations that would be found in an expected distribution. If the differences are small, the distribution fits the theoretical distribution. If the difference are large, the distribution probably does not fit the expected distribution.

Using Chi-square with the assumption of a normal distribution

1.The calculated chi-square is compared to the value in the table of constants for chi-square based on the number of "degrees of freedom."

2.If the calculated chi-square is less than the value in the table, the chi-square test passes. You can keep the assumption that the process has a normal distribution.

3.If the chi-square is larger than the value in the table, the chi-square test fails. At this confidence level, you either do not have enough data to judge the process, or you should reject the assumption that the process has a normal distribution.

For chi-square test:

Good cell defined

A cell where the expected number of observations is at least 5 based on the theoretical distribution (normal curve). If the expected number of observations is not 5 or more as per Duncan), then the cells width is increased until the expected value of 5 or more is reached. If all readings are fitting in only 1 Cell after combining Chi Square test can not be performed.

Degrees of freedom = n - 1.  where n is no of classes.

Confidence level can be set from Chart > Options to 95%, 99% and 99.1%.

Formula:

       2      K            2

 	 Chi-squareχ   = ∑ (Oi-Ei) / Ei

                              K     I=0

where K-1 is degree of freedom and K no of class intervals.

Where:

Oi  = actual frequency or number of observations in a cell

Ei = expected frequency or number of observations in a cell in the theoretical distribution

∑ = symbol for "summation."

Skewness Value

Skewness is the measure of the asymmetry of a histogram (frequency distribution).  A histogram with normal distribution is symmetrical. In other words, the same amount of data falls on both sides of the mean. A normal distribution will have a skewness of 0. The direction of skewness is to the tail. The larger the number, the longer the tail. If skewness is positive, the tail on the right side of the distribution will be longer.  If skewness is negative, the tail on the left side will be "longer."

Formulas

         N            _     3

N 	         ∑ ((Xi – X)/S)

Skewness =    --------------------  *   i =1

 	   (N-1) * (N-2)

 _

X = mean	N= No. of data points   	S= standard Deviation

Kurtosis value

Kurtosis is a measure of the combined weight of the tails in relation to the rest of the distribution. As the tails of a distribution become heavier, the kurtosis value will increase. As the tails become lighter the kurtosis value will decrease. A histogram with a normal distribution has a kurtosis of 0. If the distribution is peaked (tall and skinny), it will have a kurtosis greater than 0 and is said to be leptokurtic. If the distribution is flat, it will have a kurtosis value less than zero and is said to be platykurtic.

Formulas

            N	   _     4	     2

       N*(N+1)* ∑ ((Xi - X)/S)	      3*(N-1)

           i =1

Kurtosis =    ---------------------------             -       --------------

  (N-1)(N-2)(N-3)                         (N-2)(N-3)

 _

X = mean,  	   N = No. of data points  	S= standard Deviation

Non Parametric method for PPK Calculation

Formula:

Pp = (USL - LSL)/(P(0.99875) - P(0.00135))

Ppk = Min {(P(0.5) - LSL)/(P(0.5) - P(0.00135)), (USL –P(0.5)) / (P(0.99875) - P(0.5))}

Box Cox Transformation for CPK Calculation

Box-Cox is a method of transformation of data to make it normal or more nearly normal.

Formula:

     λ

Yi (λ) = (Xi – 1) / λ

After transformation of data using above method Cp, Cpk, Pp, Ppk is calculated with standard formulas.

λ is Calculated using log likely hood function. Which is

The logarithm of the likelihood function

  	       n               _       2                    n

      	(-n/2)LN [∑(Xi(λ)-X(λ))/n]+( λ-1) ∑LN(Xi)

          	                  I =1                                         I =1

                	_              n

Where X(λ)=1/n ∑ Xi(λ)

      	   i=1

Note-

λ value is restricted from –10 to + 10.

If data contains any negative values Box Cox Transformation can not be performed.

To run Box Cox transformation Ms-Excel needs to be installed on the machine.

PPM Calculation

Formula:

                	             _

Calculate Z upper=(USL –X)/ σ

Locate the value for Zupper in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % above the upper spec Limit.

                                                   _

Similarly calculate Z Lower=(X-LSL)/ σ

Locate the value for Z lower in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % below the lower spec Limit.

DPM=(Zupper + Zlower) * 10,000


NewTopic 2


SPC Formula

Standard SPC Formulas

                     _

SD = R/D2

Cp = USL – LSL / 6 * SD

Cpk = min (Cpl, Cpu)

                _

Cpl = X – LSL / 3 * SD

                            _

Cpu = USL - X / 3 * SD

SD (n-1) (for n-1 samples) = sqrt [((X12 + X22 +…Xn2) – n (XBAR)2 ) / (n-1)]

Pp = (USL – LSL) / 6 * SD (n-1)

Ppk = min (Ppl, Ppu)

                 _

Ppl = (X – LSL) / (3 * SD (n-1))

                              _

Ppu = (USL – X) / (3 * SD (n-1))

FOR  XbarR Chart :

                    _

LCLx = X – (A2 * R)

                    _

UCLx = X + (A2 * R)

UCLr = (D4 * R)

LCLr = (D3 * R)

FOR  XbarS Chart :

UCLs = B4 * S

LCLs = B3 * S

                    _

LCLx = X - (A3 * S)

                    _

UCLx = X + (A3 * S)

S = SD (n-1) for each sub-group

FOR  XMR Chart :

UCLmr = D4 * R

LCLmr = D3 * R

UCLx = X + E2 R

LCLx = X - E2 R

Chi-Square Goodness-of-Fit Test

In SPC, the chi-square statistic is used to determine how well the actual distribution fits the expected distribution. Chi-square compares the number of observations found in each cell in a histogram (actual) to the number of observations that would be found in an expected distribution. If the differences are small, the distribution fits the theoretical distribution. If the difference are large, the distribution probably does not fit the expected distribution.

Using Chi-square with the assumption of a normal distribution

1.The calculated chi-square is compared to the value in the table of constants for chi-square based on the number of "degrees of freedom."

2.If the calculated chi-square is less than the value in the table, the chi-square test passes. You can keep the assumption that the process has a normal distribution.

3.If the chi-square is larger than the value in the table, the chi-square test fails. At this confidence level, you either do not have enough data to judge the process, or you should reject the assumption that the process has a normal distribution.

For chi-square test:

Good cell defined

A cell where the expected number of observations is at least 5 based on the theoretical distribution (normal curve). If the expected number of observations is not 5 or more as per Duncan), then the cells width is increased until the expected value of 5 or more is reached. If all readings are fitting in only 1 Cell after combining Chi Square test can not be performed.

Degrees of freedom = n - 1.  where n is no of classes.

Confidence level can be set from Chart > Options to 95%, 99% and 99.1%.

Formula:

       2      K            2

 	 Chi-squareχ   = ∑ (Oi-Ei) / Ei

                              K     I=0

where K-1 is degree of freedom and K no of class intervals.

Where:

Oi  = actual frequency or number of observations in a cell

Ei = expected frequency or number of observations in a cell in the theoretical distribution

∑ = symbol for "summation."

Skewness Value

Skewness is the measure of the asymmetry of a histogram (frequency distribution).  A histogram with normal distribution is symmetrical. In other words, the same amount of data falls on both sides of the mean. A normal distribution will have a skewness of 0. The direction of skewness is to the tail. The larger the number, the longer the tail. If skewness is positive, the tail on the right side of the distribution will be longer.  If skewness is negative, the tail on the left side will be "longer."

Formulas

         N            _     3

N 	         ∑ ((Xi – X)/S)

Skewness =    --------------------  *   i =1

 	   (N-1) * (N-2)

 _

X = mean	N= No. of data points   	S= standard Deviation

Kurtosis value

Kurtosis is a measure of the combined weight of the tails in relation to the rest of the distribution. As the tails of a distribution become heavier, the kurtosis value will increase. As the tails become lighter the kurtosis value will decrease. A histogram with a normal distribution has a kurtosis of 0. If the distribution is peaked (tall and skinny), it will have a kurtosis greater than 0 and is said to be leptokurtic. If the distribution is flat, it will have a kurtosis value less than zero and is said to be platykurtic.

Formulas

            N	   _     4	     2

       N*(N+1)* ∑ ((Xi - X)/S)	      3*(N-1)

           i =1

Kurtosis =    ---------------------------             -       --------------

  (N-1)(N-2)(N-3)                         (N-2)(N-3)

 _

X = mean,  	   N = No. of data points  	S= standard Deviation

Non Parametric method for PPK Calculation

Formula:

Pp = (USL - LSL)/(P(0.99875) - P(0.00135))

Ppk = Min {(P(0.5) - LSL)/(P(0.5) - P(0.00135)), (USL –P(0.5)) / (P(0.99875) - P(0.5))}

Box Cox Transformation for CPK Calculation

Box-Cox is a method of transformation of data to make it normal or more nearly normal.

Formula:

     λ

Yi (λ) = (Xi – 1) / λ

After transformation of data using above method Cp, Cpk, Pp, Ppk is calculated with standard formulas.

λ is Calculated using log likely hood function. Which is

The logarithm of the likelihood function

  	       n               _       2                    n

      	(-n/2)LN [∑(Xi(λ)-X(λ))/n]+( λ-1) ∑LN(Xi)

          	                  I =1                                         I =1

                	_              n

Where X(λ)=1/n ∑ Xi(λ)

      	   i=1

Note-

λ value is restricted from –10 to + 10.

If data contains any negative values Box Cox Transformation can not be performed.

To run Box Cox transformation Ms-Excel needs to be installed on the machine.

PPM Calculation

Formula:

                	             _

Calculate Z upper=(USL –X)/ σ

Locate the value for Zupper in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % above the upper spec Limit.

                                                   _

Similarly calculate Z Lower=(X-LSL)/ σ

Locate the value for Z lower in standard normal table.

Multiply (1-Z-value) by 100 to get the theoretical % below the lower spec Limit.

DPM=(Zupper + Zlower) * 10,000


Partwise Daily Cp/Cpk or Pp/Ppk Report

Daily Cp Cpk/ Pp Ppk Report will display the Cp cpk or Pp Ppk details for all the selected parameters defined in all the Job or work orders created between the specified period.

Click on Report -> Daily Cp Cpk/ Pp Ppk Report menu item. A screen for accepting report Dates will be launched. Specify the required period by entering Period From and Period To. Select the required Parameter from the parameter list. Select Cp-Cpk data or the Pp-Ppk data as per the requirement. Click OK to confirm the selection and proceed with the generation of report. Click Cancel to exit.

Report will display company name and report name in the report title. Right hand corner of report will display current date in dd-mmm-yyyy hh:mm:ss AM/PM format. From and To Date selected from the Report dates screen will be displayed.

This report will display the Parameter names, date of Job/WorkOrder creation, Part no, Workorder no, Machine no, Operator code, Process code, Cp and Cpk or Pp and Ppk. Cp and Cpk or Pp and Ppk will be categorized under three columns - >1.33, 1.33, <1 each.

Cp or Pp column will not be display when the parameter is single sided


Dashboard_CpCpk_Screen

It displays Job related parameters information for selected cell/location gets display.

This Page has Job No, Machine No., Part No, Parameter, Process Status, Cp and Cpk.

When Parameter is 100% inspection then display the value of Pp, Ppk.

When Parameter is sampling then display the value of Cp, Cpk.

When Parameters are only 100% inspection then display the header is Pp, Ppk.

When Parameters are Sampling and 100% Inspection then display the header is Cp, Cpk.

Process status will display the color depending upon the Control Limits and Cpk or Ppk value from XBarRSetting. If Cpk or Ppk value is blank from XBarRSetting then Cpk or Ppk value will be considered as 1.66

In Control means - Xbar of sample is within control Limit

Not in Control - Xbar of sample is Out of control Limit

Capable - Cpk > 1.66

Not Capable - Cpk < 1.66

Process Status will have color Green when Process Status is In Control & Capable.

Process Status will have color Yellow when Process Status is Not In Control but Capable.

Process Status will have color Orange when Process Status is In Control & Not Capable.

Process Status will have color Red when Process Status is Not in Control & Not Capable.

Some samples has been taken and when user click on Process Status for that parameter then user can see the Control Charts in different page for the selected parameter. Sample has not been taken and when user click on Process Status for that parameter then display the message ‘No Reading taken’. When reading has not taken for a particular parameter then the Process status will be disabling and display the default color i.e. other than Green, Yellow, Orange and Red.

If user configure ‘Display Cpk or Ppk value’ to zero (0) in Job Creation then  Cp, Cpk or Pp, Ppk value will be calculated and display for all samples.

If user put the sample no 20 then system will calculate for last 20 samples.


Control_Chart_OCX

It provide details about the Control Chart ocx for the selected parameter from the Dashboard Cp,Cpk web Page. It displays Statistical analysis, Histogram, X Bar R chart and readings in the grid.

The page has Refresh button, Histogram, Statistical Analysis, XBarR Chart, Grid for displaying Readings and buttons for scrolling the readings from the grid. Parameter description can be seen at the bottom of the page.

User can see the different options of Charts by clicking right button of mouse on XBarR Chart. User can select any charts from those options.

If user selects X-chart then grid has two rows i.e. Time and X1 (Reading). If user selects XBarR Chart then grid display 7 rows if sample size is 4. i.e. Time,x1,x2,x3,x4,Average and Range. Header of the grid has Date/Sample number.

When user moves mouse pointer to a particular sample, user can see Sample No, X Bar, Date, Time and Readings. If Remark is present user can see that remark also. When user moves mouse pointer to a particular sample then first row will be selected from the grid of the selected sample.

If Remark is entered for the sample of the parameter then user can see the vertical line for that sample.

Statistical Analysis will display Capability Indices Cp, Cpk. Specifications USL, LSL, and N - Number of Readings

Out of Specs Above, Below. Max, Mean, Min, DPM, Skewness and Kurtosis.

When Pp, Ppk will be display then dpm will use the standard deviation by Square root method. When Cp, Cpk will be display then dpm will use the standard deviation by Rbar by d2 method.

Red Lining –

When user clicks on Red Lining button floating toolbar will get display, which contains 3 buttons 1.Marking 2.Add Comments and 3.Exit.

When user clicks on ‘Marking’ Toolbar, user will be able to draw circle/line when user moves the mouse by pressing left button anywhere in the page to highlight the specified area.

When user clicks on ‘Add ’ then text box will get display nearby where last red lining is done. User can increase/decrease the height or width of text box by moving Up-Down arrow or Left-Right arrow.

When use click on ‘Exit’ button Red Lining Toolbar will get Invisible.

Email –

When user clicks on Email button, ‘Fill Email Details’ frame will get display which contains Send, Reset and Exit button.

In this frame, SMTP Server, Sender Email, Sender Password, Port will get populated based on the data inserted in Configure Sender EmailID screen of Email-SMS Project, this value user can change if required.

User has to enter Recipient Email, Cc: Email (Optional), Subject and Message. Attachment text box will show the current snapshot of .jpg image where system copied the snapshot of page. Status list box shows the processing of Email while sending the email. Just below Status list box system will show the message ‘Message (Count) Messages sent in <No. of> sec’.

Reset button will clear the all contents in textbox, listbox that is below Port text box.Exit button will exit from Email.


Email Escalation Master
Email Escalation Master (Dash Board)

Use this option to crate Email Escalation hierarchy like President, General Manager and Unit Manager and then assign unit to Unit Manager.

Select Plant and Click on Add for assigning President. Click on Check box to select the president and Click on Save.

Select President and Click on Add for assigning General Manager. Click on check box to select the General Manager and Click on Save.

Select General Manager and Click on Add for assigning Unit Manager. Click on Check box to select the Unit Manager and Click on Save.

Select Unit Manager and Click on Add for assigning Units. Click on Check box to select the units and Click on Save. After assigning Unit system will show all those cells which are assigned in the Dashboard.

Screen has Add, Modify and Delete option for President, General Manager, Unit Manager and Unit. User cannot add, modify or delete Location or Cell node.

User can add President by selection of Plant (Parent), which is populated on right side of list box, which is populated from contact user screen, which have ‘President’ category. User can add multiple presidents.


Data Collection

Through Data Collection application, Pro-QMS collects the data from .csv/. xls files, write the log file if data is not valid & move the files from original folder to History folder.

Data Collection screen will contain 2 buttons namely Scan CSV File, Close button and Grid, which contain 7 columns namely, Job. No, Machine, Part, Parameter, Reading, Sample No, Reading No. And bottom of screen contain legend of Within Control Limit, Out Of Control Limit and Out of Specification.

Close button will use for closing the application.

When user clicked on Scan CSV File button system will move all the files from Shared folder and move it to Process File folder. Once all files are moved to Process File folder then system sorts the file with ascending order of date and time. System reads a file one by one & dumps in respective cell as per the mapping sequence, which was defined in QAP and updates the Sample No, Reading No respectively.

Once file is scanned & data dumping has been done, system will move the file from Process Files folder to \HISTORYFILES \ PARTNO \ MONYY folder.

In case of Tata Motors Engine shop we also copy file in the ProQMSBackup\MMMYYYY of share folder path.

If job is not present for the part then system moves the file in \HISTORYFILES\Unscanned Folder. If data is not proper then puts in the current day Log file in the Log Files folder. If reading is not within the range of configure Percentage then system puts in the different table.

 After scanning all files, system will write how much time is required for scanning and storing the files in the Process Time folder of that day.

Start time 	-

End   Time 	-

Total Time 	-

Job No., Machine No row-column for start of every job show in 3 alternate color randomly.

G_ExcelSCL = True

In case of SCL Data collection screen will contain 2 buttons namely Scan File, Close button and Grid, which contain 7 columns namely, Job. No, Machine, Part, Parameter, Reading, Sample No, Reading No. And bottom of screen contain legend of Within Control Limit, Out Of Control Limit, Out of Specification. Just below the grid, Tab control will display number of tab which will depending upon the share folder name selected from the share folder screen. Each Tab contains a grid, which will contain 3 columns, namely All File, Scan File, and Unscan File.

Close button will use for closing the application.

When user clicks on Scan File button system will move all the files from Shared folder and move it to Process File folder. Once all files are moved to Process File folder then system sorts the file with ascending order of date and time. System reads a file one by one, extract the Part No from predefined cell, load all jobs for selected part no & station no. Stores the data as per the mapping sequence number and after reading completes system clears the grid & then read next file. If user selects two folder from Shared folder selection screen, once scanning for 1st folder start, then system will set the focus on 1st tab of grid and show files one by one in ‘All File’ column, once file scanned without any problem system will show same file in ‘Scan File’ column otherwise in ‘Unscan File’ column and simultaneously data will dumps in respective cell as per the mapping sequence, which was defined in QAP and updates the Sample No, Reading No respectively.

Once file is scanned & data dumping has been done, system will move the file from Process Files folder to \HISTORYFILES \Shared FOLDERNAME \PARTNO \ MONYYYY folder. E.g. – Application Path \SCLExcelFiles\HistoryFiles\CMM1\12236-RNA-A000\ Dec2010

If job is not present for the part then system will not load the job in a grid & moves the file in \HISTORYFILES \UNSCANNED \Shared FOLDERNAME \MONYYYY Folder and write the log file for current date in same folder by mentioning the Reason PartNo & file name.

If Part No is blank then system will not load the job in a grid & moves the file in \HISTORYFILES \UNSCANNED \FOLDERNAME \MONYY Folder and write the log file for current date in same folder by mentioning the Reason & file name.

If data is not proper then puts in the current day Log file in the Log Files folder. If reading is not within the range of configure Percentage then system puts in the different table.

After scanning all files from CMM1 folder, system will write how much time is required for scanning and storing the files of CMM1 folder.

Part Selection –

In case of Tata Motors User launch the CSV Data Application then system will show a grid with two column namely Part & Select and OK & Cancel button.

Part column will get populate which is based on Job Created for selected station.

Select all option will provide to select all the Part or User can select the Part by click on Select check box.

When user selects part then Ok button will get enabled.

On click of OK button, system will launch Data Collection for all jobs of the selected Part.

On click of Cancel button, system will unload the application.

In case of SCL User launch the Data collection Application then system will show a grid with two columns namely Shared Folder Path and Select & OK & Cancel button.

Share Folder Path column will get populates based on Share Folder Path screen.

Select all option will provide to select all the Shared Folder Path or User can select the Share Folder Path by click on Select check box. Systems will allow to selects the share folder paths, which have CMM1 or CMM2 folder name.

When user checks Shared Folder Path from Select column then Ok button will get enabled.

On click of OK button, system will launch Data Collection screen.

On click of Cancel button, system will unload the application.

G_HeatTreatment = True

When user has started the application, system will launch data collection screen with all created jobs in a grid. Grid have 7 columns namely Job No, Machine No, Part, Parameter-Description, Reading, Sample No, Reading No. Screen has 2 buttons namely Scan File, Close and one progress bar which show status of Parameter No/Parameter Count & parameter name and one text field for entering default hrs which is used for taking reading time (E.g. Current Time + Request time – Default Hrs (Request time *2) = Reading Time)

When user clicks on ‘Scan File’ button, based on last reading date-time and request time, system will send server name, archive path, start date, start time, end date, end time, average type and PartParaCode to PlantScape dll for getting data. Once get the data, system will dump for selected parameter by incrementing the sample no, reading no. Once data dumping for selected parameter is over, system will read data for next parameter and so in that way cycle will get proceeded.

E.g. Request Time – 30 Min, Average Type – 1 Min, Last Reading Time – 06.00 PM

So at 06.30 PM systems will send the required parameter as SERVERNAME, ARCHIVEPATH, 12/05/2011,06.00 PM, 12/05/2011, 06.30 PM, 6 (Average Type), PARA1 to Plantscape.dll to get required data in an array.

While dumping the data from an array, system will checks data is numeric or not if it is invalid then system will write in the log file for same & will not be dumped the data and move to next reading in an array.

While dumping the reading, users can stop the data by pressing Esc key. When user presses Esc key, system will prompt the user ‘Do you want to stop the data dumping?’ with Yes/No button if user presses Yes then system will stop the data collection otherwise continue the data dumping.

After dumping last reading for a parameter, JobParameter table will get updated with LastAccessDate. E.g. If user closed the data collection screen then next time data collection will start for a parameter which have blank record in a field.

E.g. 	Below one example demonstrates how system will work.

(Request Time - 30 Min, Average Type - 1 Min, Current Time - 10.00 AM

Display minutes to be reduced from current time - 60

Read data reduced from current time In Min – 0)

Sr. No 	Start Time	End Time	DumpingFinish	LastTime

1	09.30 AM	10.00 AM	10.10 AM	10.00 AM

2	10.00 AM	10.30 AM	10.35 AM	10.30 AM

3	10.30 AM	11.00 AM	11.35 AM	11.00 AM

4	11.00 AM	11.30 AM	11.45 AM	11.30 AM

In case of Sr. No 1, Reading time will be 09:01 AM, 09:02 AM, and 09:03 AM i.e. Start time + Request Time + 1.

User has closed the data collection. User has started the data collection screen and click on Scan file, Data is already dumped for the requested period, System will display the message on screen as ‘Data already dumped, next request time is 13-Jun-2011 06:26:00 PM’

System will dump the data day wise i.e in a scenario when Start Time is 11:45 PM and End Time is 12:15 AM for Request Time is 30 Min, system will dump the data in 2 slab i.e 1st slab start from 11:45 PM to 11:59 PM and 2nd slab start from 12:00 AM to 12:15 AM and also user has not dumped the data for last 8-10 day then system will dumped the data day by day to 1st parameter and so on.

Suppose Average Type is 1 Min and Request period is 30 Min and if the Plants cape server sends the data of 20 readings instead of 30 readings then system should store the data from 10.00 to 10.30 but in this case from server data received is of 20 readings so system will store the data from 10.10 to 10.30 instead of 10.00 to 10.20. It will put in the log file data is not stored from 10.00 to 10.10 as less data is received from server.

For selected period, Plantscape server is unable to give the data then system will flash the message on label ‘Server is not responding’ and it will blink continuously till Plantscape server will give the data and write the log file for same in Application Path\HeatTreatment\ServerLog\11-Jul-11.txt.

Furnace Stop/Start – When furnace gets stopped then user has to stopped the data dumping otherwise Out of Specs data will get dumped, for that reason system has provided the facility to stop & start the furnace. (‘Stop Furnace’/ ‘Start Furnace’)

When user clicks on ‘Stop Furnace’ button then system will show new screen to enter Furnace Stop Date, Time and Stop Remarks. Once user has stopped the furnace, label of ‘Stop Furnace’ change to ‘Start Furnace’ then without start of furnace user cannot dump the data. Stop Furnace Date-Time should be greater than Last Access Date.

When user click on ‘Start Furnace’ button then user has to enter Furnace Start Date, Time, Start Remarks then label of ‘Start Furnace’ change to ‘Stop Furnace’. Start Furnace Date – Time should be greater than last ‘Stop Furnace Date Time’.

When user has dumped the data for few parameters and click on ‘Stop Furnace’ button then system will prompt the message ‘Furnace stop is valid only when user has dumped the data for all parameters’ and then operation will get cancelled.


Desktop Alert

Desktop alert facility displays pending corrective action list cell wise for windows user category. On mouse move of tray icon, system will show ‘Desktop Alert’.

Tray Icon for Desktop Alert screen has three buttons namely Start Desktop Alert, Stop Desktop Alert and Exit.

If windows login user has category President/General Manager/Unit Manager (P/G/U) which was defined in Email application of Contact/User screen and is available in Email Escalation Master screen then system will launch the Pending Corrective Action screen and Desktop Alert screen show disable ‘Start Desktop Alert’, enable ‘Stop Desktop Alert’ and ‘Exit’ menu button.

If user clicks on ‘Stop Desktop Alert’ button then system will close Pending Corrective Action screen, disables ‘Stop Desktop Alert’ button/menu and enable ‘Start Desktop Alert’ button.

If user clicks on ‘Start Desktop Alert’ button then system will show Pending Corrective Action screen, disables ‘Start Desktop Alert’ button/menu and enable ‘Stop Desktop Alert’ menu.

Pending Corrective Action screen will get launch depending upon the desktop frequency defined for the user, on left hand side system will show a tree view structure for selected windows user i.e. President, General Manager, Unit Manager, Unit, Cell/Location and on right hand side system will show a 2 tab namely Pending Corrective Action and No Data Collection. No Data Collection checkbox will be used for selection of No Data Collection tab.

If Window User has category President/General Manager/Unit Manager (P/G/U) and is not available in Email Escalation Master then system will prompt the message and enable ‘Start Desktop Alert’, disable ‘Stop Desktop Alert’ menu.

Pending Corrective Action Tab –

The tab contains grid, which populate the trend of 1 to 28 which are configured for selected cell and second tab contain grid, which populate the trend of 29-30 for selected cell. By default ‘No Data Collection’ checkbox is unchecked and 2nd Tab will be disabled.

When user unchecked ‘No Data Collection’ then 1st tab will get enabled and 2nd Tab will get disabled and when user checked ‘No Data Collection’ then 1st tab will get disabled and 2nd Tab will get enabled.

No Data Collection Tab grid contains 2 trends like Line not running and No Data Collection in last 24 hrs.

Grid contain 9 column namely Machine No, Job No, Part Code, Parameter, Trend, Sample No, Sample Date, Sample Time, Station No. Grid is not editable.

Tree structure & grid will populate based on user Category and frequency of unit Manager, General Manager and Pending days for Nonconformity, which was defined in the Frequency of Email/SMC screen.

No Data Collection Tab –

Based on Desktop Frequency, system will refresh the grid along with tree to show the latest record.

Unit Manager can see all records of Pending nonconformity corrective action of defined Units.

General Manager can see records of Pending nonconformity corrective action from (Current day/time – Unit Manager Frequency-Non Conformity Pending day-12 Hrs) to (Current time/day – Unit Manager Frequency-12 Hrs) of which are defined for different units.

President can see records of Pending nonconformity corrective action from (Current day/time – General Manager Frequency-Non Conformity Pending day-12 Hrs) to (Current time/day – General Manager Frequency-12 Hrs) of which are defined for different General Manager and units.

Under Unit node user can see different Cell. Cell has different Machine. When user selects Cell, system will show pending corrective action machine wise in that cell.

Hierarchy will be President -> General Manager -> Unit Manager -> Cell.


Monthly Database Backup

Select File/ Monthly Database Backup from the Main Menu.

The Monthly Database Backup option is used to create the database of name Month Year (mmYY) and constraint, stored procedure and will copy data of configured master and transaction to newly created database and create System DSN for same.

User has to select the month from Month combo box and enter year in Year textbox and click on OK button, First of all system will check TableName.txt, DatabaseScript.sql, StoreProcedureScript.sql is present or Not.

If one of 3 files doesn’t exist then system will prompt the message and write the log file for which doesn’t exists and stop the database backup.

If all 3 files exist then system will check selected database is present at current database server.

If database is not present then system will create the database of entered Month Year, add tables, constraints, stored procedures, copied configured table from current database to newly created database and at last system will create system DSN for newly created database.

While copying the table record, system will check configure table is present in current as well as in newly created database, if not then system will write the log file for same and at last system will prompt the user ‘Please check log file MMMYY.log’ otherwise prompt the user ‘Database created successfully’.

If database is present then system will flash the message ‘Database Already Present’.

When user clicks on Cancel button or Close (X) button of screen then system will unload Monthly Database Backup Screen.

System has facility to take backups for last 3 month only.